Process for Manufacturing Improved Dispensing Devices

ABSTRACT

The present invention relates to a method for the manufacture of a lavatory dispensing device useful for the delivery of at least one treatment composition, preferably a cleaning composition and/or a sanitizing composition to a sanitary appliance.

The present invention relates to improvements in manufacture ofdispensing devices. More particularly the present invention relates toimproved processes for the manufacture of a device used to deliver atreatment composition to a sanitary appliance, particularly to a toilet,which treatment composition contains one or more chemical constituentse.g., coloring agents, cleaning agents, disinfecting agents, anti-limescale agents in the form of a block. The treatment composition is formedby water contacting the block of the device coming into contact with theone or more chemical constituents; the block provides for the long termrelease of the one or more active agents during sequential contacts withwater contacting the block of the toilet dispensing device.

Since the advent of sanitary appliances and in particular modern flushtoilets, there has been a continuing need in the art to provideeffective ways to maintain these appliances in a satisfactory conditionbetween uses. The art is replete with devices which are intended to beused as “in the bowl” (or ITB) or “in the cistern” (or ITC) in order toprovide a coloring and/or cleaning and/or fragrancing and/or sanitizingeffect to such sanitary devices, particularly toilet bowls.

One common approach known to the art is to provide a device which is atleast immersed within the cistern or tank of a toilet, which may beeither placed wholly within the interior of the toilet such as byplacement at the bottom of a toilet tank so that the entire device iswholly immersed in water when the tank is full, or is at least partiallyimmersed within the water present in a toilet tank, such as wherein sucha device is suspended from a part of the toilet tank, such as a lip orrim of the tank. Such are generally referred to as ITC devices.

A further common approach known to the art is to provide a device whichis suspended from the rim of the toilet bowl and which is placed at ornear the interior sidewall of the toilet bowl. Such are generallyreferred to as ITB devices. Such a device is designed to typicallydispense a treatment composition to the interior of a toilet when a gelor block compositions is contacted with flushing water, or alternately,dispensing a fragrancing composition to the toilet bowl which isintended to counteract or mask malodors. Typically such devices includea hanger portion which is used to suspend a cage portion from the rim ofthe toilet bowl, such that the cage portion is positioned within thepath of flowing water which is dispensed with each flush operation ofthe toilet. The cage portion typically comprises a plurality of holes orapertures which permit for the flush water to both enter and to exit thecage portion of the device. Typically a solid block composition or a gelcomposition is present within the cage. The solid block compositionand/or gel composition typically comprises one or more cleaningconstituents, e.g., one or more surfactants which provide a goodcleaning and/or foaming benefit. Often the solid block compositionand/or gel composition comprises a fragrance constituent as well whichis provided to provide some degree of malodor suppression. For most suchdevices, the use of a cage is essential as in the case of a gelcompositions, as gels are not self supporting and would not be usefulwithout the physical supporting structure provided by the cage. Withregard to solid block compositions, such compositions are notoriouslyprone to weakening and softening over time and most are known to sell orsag over their lifetime, particularly when approaching the end of theiruseful service life. The cage acts then as a porous receptacle andsupport for said blocks which would otherwise prematurely soften ordisintegrate and fall into the toilet bowl and be flushed away beforetheir composition is substantially consumed.

While the use of a cage is beneficial, the use of a cage is not withoutattendant problems. The use of a cage requires increased material costs,and additional manufacturing steps. Further as such ITB devices aretypically single use type devices, once the gel or block composition isconsumed or otherwise exhausted, the consumer discards the entire ITBdevice which is wasteful and contributes to the problems associated withproper garbage disposal. With regard to costs, in most conventional rimsuspended lavatory devices comprising a hanger portion and a cageportion, the bulk of the material is typically used to form the cage. Assuch cages are typically fabricated from a synthetic polymer, suchrequires specific molding operations in order to form the rim suspendedlavatory device, and to fill the cage with the solid block compositionand/or gel composition prior to use and or sale.

Known to the art are rim suspended lavatory devices which are lavatoryblocks of paradichlorobenzene which provide no cleaning benefit, butprovide only a fragrancing benefit. Such blocks typically erode persublimation of the paradichlorobenzene and/or by contact with flushwater. Such rim suspended are lavatory blocks of paradichlorobenzene aretypically packaged as a solid block or cake having extending from oneside a loop of bendable wire. A portion of the bendable wire is embeddedwithin the paradichlorobenzene block. The consumer is required to formthe wire into a hanger appropriate to the particular geometry of theirtoilet so that the paradichlorobenzene block is positioned with theinterior of the toilet bowl.

Apart from the foregoing, while the elimination of a cage from aconventional, nm suspended lavatory device would be beneficial such arenot believed to be known. This is due to the fact that surfactantcontaining solid block compositions are known to soften quickly and thisin turn eliminates any reasonable prospect of a useful service life whenused in conjunction with a toilet absent the support provided by thecage.

Thus, while certain known-art dispensing devices provide beneficialmalodor treatment effects, there is nonetheless a real and continuingneed in the art to provide still further improved devices which canprovide to a sanitary appliance a useful treatment benefit, preferably auseful cleaning benefit.

The present invention, in its various aspects, provides a method for themanufacture of a lavatory dispensing device useful for the delivery ofat least one treatment composition, preferably a cleaning compositionand/or a sanitizing composition to a sanitary appliance, e.g. a toiletbowl. The device can be used either as an ITC type device, or an ITBtype device for a sanitary appliance such as a urinal, toilet tank ortoilet bowl. In certain preferred embodiments the device according tothe invention is used as an ITB type device. In certain alternatepreferred embodiments the device according to the invention is used asan ITC type device.

According to a first aspect of the invention there is provided a methodfor the manufacture of a cageless lavatory device comprising a hangerand a compressed solid block comprising one or more chemicalconstituents for use with a sanitary appliance.

According to a second aspect of the invention there is provided a methodfor the manufacture of a cageless lavatory device comprising a hangerhaving a part adapted to be suspended from a part of a sanitaryappliance, and a compressed solid block comprising one or more chemicalconstituents, wherein the device is adapted to be suspended within theinterior of the toilet bowl.

In accordance with a third aspect of the invention there is provided amethod for the manufacture of a cageless lavatory device comprising ahanger adapted to be suspended from the rim of a sanitary appliance,particularly a toilet bowl, and block comprising at least one or morechemical constituents adapted to be suspended within the interior of thetoilet bowl, wherein the block composition is long lasting.

According to a fourth aspect of the invention there is provided a methodfor the delivering a treatment composition to a sanitary appliance,especially preferably, to the interior of a toilet bowl, which processcomprises: providing a cageless lavatory device produced according toone or more of the improved methods described hereinafter, the devicecomprising a hanger adapted to be suspended from a part of a sanitaryappliance, and a compressed block comprising at least one or morechemical constituents adapted to be suspended within the sanitaryappliance, and, periodically flushing water about the exterior of thecompressed block to elute at least one chemical constituent to form atreatment composition with said water which treatment composition isused to treat a part of the sanitary appliance.

According to a fifth aspect of the invention there is provided acageless lavatory device comprising a hanger having a part thereofadapted to be suspended from a part of a sanitary appliance,particularly from a part a toilet cistern or toilet tank, and acompressed solid block comprising one or more chemical constituents,wherein the device is adapted to be suspended within the interior ofsaid cistern or tank.

According to a sixth aspect of the invention there is provided acageless lavatory device comprising a hanger having a part thereofadapted to be suspended from a part of a sanitary appliance,particularly from a part a toilet cistern or toilet tank, and acompressed solid block comprising one or more chemical constituents,wherein the device is adapted to be suspended within the interior ofsaid cistern or tank.

In accordance with a seventh aspect of the invention there is provided acageless lavatory device comprising a hanger adapted to be suspendedfrom the rim of a sanitary appliance, particularly a part of a toiletcistern or toilet tank such as from a part of a rim of a toilet cisternor toilet tank comprising at one or more chemical constituents adaptedto be suspended within the interior of said cistern or tank, wherein theblock composition is long lasting.

In accordance with a still further aspect of the invention there isprovided as a vendible article, a cageless lavatory device comprising ahanger and a compressed solid block comprising one or more chemicalconstituents for use with a sanitary appliance, particularly a toiletproduced by one or more of the processes defined herein.

These and other aspects of the invention will be more evident from areading of the following specification.

Broadly defined, the present invention relates to a method of making acageless lavatory device comprising a hanger and a compressed solidblock comprising one or more chemical constituents for use with asanitary appliance, as well as methods for its use of the cagelesslavatory device in the treatment of sanitary appliances, particularlytoilets.

The inventors have surprisingly found that notwithstanding the existingprejudice in the prior art which dictates the use of cages to supportand contain lavatory treatment blocks, that it has been discovered bythe inventors that it is now possible to fabricate cageless lavatorydevices which comprise a hanger and a compressed solid block compositiondepending from the hanger which solid block compositions comprise one ormore chemical constituents, preferably at least a surfactantcomposition, which cageless lavatory devices are useful in providing atreatment composition to a sanitary appliance over repeated flushes ofwater and/or repeated immersions in water wherein the compressed blocksto not fall away from or break away from the hanger for a reasonableduration of time. This result is unexpected as the prior art dictatesthe use of a cage as previously described, and as is also widely knownin the art to support a lavatory block composition over its usefullifespan, particularly wherein the lavatory block comprises one or moresurfactants. As is known to the art, with repeated flushes of water,many such surfactant containing lavatory blocks tend to swell and/orsoften and very frequently disintegrate or slump, thus requiring a cageto contain the lavatory block. Alternately as is known in the art, withlong term immersion in water such as in a toilet cistern or toilet tank,such surfactant containing lavatory blocks tend to swell and/or softenand very frequently disintegrate or slump, thus requiring a cage tocontain the lavatory block.

The inventors have discovered that cageless lavatory devices whichcomprise a hanger and a compressed solid block composition dependingfrom the hanger which solid block compositions include one or morechemical constituents, preferably at least a surfactant composition, maybe formed by a process which contemplates: (a) forming a mass comprisingat least one or more chemical constituents; (b) compressing a quantityof the mass to encase a portion of the hanger. Optionally butpreferably, the mass comprising the at least one or more chemicalconstituents is mixed and extruded into a preform shape, thereafter aportion of the hanger is inserted into the preform shape or between aplurality of preform shapes, and subsequently the perform shape(s) arecompressed in a die to provide the final form of the compressed solidblock composition of the cageless lavatory device. The compressed solidblocks are retained on a part of the hanger without the need of anenclosing cage, as well as without the need of any separate adhesivematerial or composition which is placed between the compressed solidblock and the part of the hanger which the compressed solid blockcontacts.

In its simplest form the hanger is merely an article which comprises atone end, a hook end which is adapted to or configured to suspend thehanger from a part of a sanitary appliance. The hanger is preferablyconfigured so to permit its use either as an ITB device or as an ITCdevice. The hanger also includes a plate which is adapted to be embeddedwithin the compressed solid block composition. While the hook end may beintegrally formed and approximate to the plate, quite frequently thehanger includes an intermediate stalk connecting the hook end with theplate. The hanger itself may be a single element of a unitaryconstruction, or alternately, may be formed from a plurality of elementswhich are adapted to be linked or connected together. When the hanger isformed from two or more such discrete elements, the individual elementscan be affixed, attached, or linked together to ultimately form thehanger of the invention. The cageless lavatory device of the inventionmay be provided as a multiple-use article, wherein the consumer retainsa part said device on the sanitary appliance, but replaces a part of thesaid device periodically as may be needed. In such a configuration,usually a part of the hanger is retained and reused by a consumer, butupon consumption of the compressed solid block, a new compressed solidblock is provided to the sanitary appliance where it may be removablyaffixed to the retained part of the cageless lavatory device. Mostconveniently however the hanger is a single piece article.

With regard to the hook end, it is to be understood that the hook end ofthe hanger can be of any configuration which is suitable to provide ahook-type support for suspending the plate and the compressed solidblock within the interior of a sanitary appliance. Ideally, the hook isconfigured such that it is adapted to be suspended over at least a partof the rim of sanitary appliance. Such may be a rim of a urinal, atoilet bowl, or toilet cistern or tank. The hook may be of any suitabledimension, and as it is understood that as the configuration andgeometry of sanitary appliances vary, naturally the hook can be adaptedto suit the particular dimensional or geometric configurations oftoilets. Alternately and preferably the hook end is flexible andconfigurable to adapt to various configurations and geometries so thatit may be used with different sanitary appliances. Typically however,the hook end may be configured into a “U” shaped portion of the hangersuch that it may be used to suspend the hanger and plate bearing thecompressed solid block composition.

The hook may be provided in a rigid, preformed configuration which isnon-flexible or only sparingly flexible in order to accommodate thedimensions of the hook to a particular sanitary appliance. For examplewherein the hook is provided as a rigid, preformed configuration to beused in suspending the cageless lavatory device in an ITC applicationthe hook may be a discrete element which is dimensioned to have across-section which in adapted to accommodate a part of the upper rim oredge of a toilet cistern or toilet tank. Such a hook may merely suspendthe device on the rim, or the hook may be configured so that whenapplied to the part of the upper rim or edge of a toilet it functions asa mechanical clip such that it is generally retained at its point ofinstallation and resists accidental misplacement or movement.Additionally or alternately such a hook may further include a connectorelement which may take any physical shape or form and which isconfigured to cooperatively connect with a the remaining element orelements of the cageless lavatory device so that said remaining elementor elements may be removably affixed to such a hook. In such manner, thehook may be retained although the remaining elements, viz., the platebearing the compressed block and/or the stalk may be replaced a numberof times once the compressed block is exhausted. Any suitable mechanicalor chemical fastener means may be used to provide such a function. Byway of non-limiting example may be used any of a number of cooperatingmechanical elements such as clips, hook-and-loop fasteners, pins,springs, elastic bands, loops, eyelets as well as chemical meansincluding adhesives such as light or medium duty adhesives may be usedas the fastener means. Other fastener means not elucidated herein butknown to the art may also be used. In one preferred embodiment the hookincludes a part which includes a mortise shaped element, whichcooperates with the stalk or plate which is configured as a cooperatingtenon which is removably insertable into the mortise shaped element. Inanother preferred embodiment the hook includes a peg or hook, and thestalk or plate includes a cooperating loop or eye from which the stalkand/or plate bearing the compressed block may be suspended. The use ofsuch two-part embodiments of the inventive cageless lavatory block is incertain embodiments of the invention preferred as such provide a greatdeal of flexibility and also permits for the reuse of at least oneelement of the cageless lavatory device multiple times without requiringreplacement of the complete cageless lavatory device when a compressedlavatory block is exhausted. Thus is certain embodiments, certainelements of the cageless lavatory device may be reused, while others areintended to be single-use elements.

Conveniently however, the hook end is provided as one or morearticulated elements which can be flexed or bent from a first or a“folded” configuration to a second or “open hook” configuration. It isto be understood that according to preferred embodiments, in order tominimize the volume of the hanger and in particular the hook endthereof, the hanger may be provided in a collapsed or foldedconfiguration when placed into a package. Upon opening of the package,the consumer is then expected to easily unfold, extend, or otherwisestretch a portion of the hanger in order to form the hook end. A furtherimportant advantage is that the degree of flexibility provided into thehanger in order to provide for such a foldable and unfoldable hook endalso introduces a degree of tension when the hook end is configured tobe hung upon a sanitary appliance, and in particular the rim of aurinal, a toilet tank or cistern, or the rim of a toilet bowl. In such aconfiguration, the tension actually aids in the gripping of the hookupon the portion of the sanitary appliance upon which it is originallypositioned by the consumer. Such tension reduces the likelihood oflateral movement or translation from its initial placement by a consumerunless desired by the consumer. Thus, specific placement of the cagelesslavatory device, and a reasonable expectation that it will be retainedat or near the position in which it was originally installed by aconsumer relative upon a sanitary appliance is provided. Furthermore,the tension provided also provides for a degree of resiliency and alsoaids in the positioning of the compressed solid block at, or near, aspecific part of the sloping interior wall of a sanitary appliance,e.g., a toilet bowl. Such can be beneficially particularly due to thefact that flush water from the toilet bowl typically exits from beneaththe rim. Utilizing the tensile property of the hanger, the continuouspositioning of the compressed solid block within the path of the flowingflush water is assured under most circumstances.

As has been noted above, in certain preferred embodiments and indeed,according to most preferred embodiments a stalk exists to connect theplate with the hook end of the hanger. The stalk itself may be of anydimension or length, however when used in an embodiment of the inventionwherein the device is an ITC type device, desirably the stalk is ofsufficient length to ensure that the compressed block will be at leastpartially immersed, but preferably wholly immersed, in the water presentin the toilet tank or cistern between flushes. When the stalk is used inan ITB type device, advantageously once the hook end is suspended upon asanitary appliance, particularly the rim of a toilet bowl, the stalkextends a sufficient length to the plate such that ultimately, thepositioning of the hook and the length of the stalk as such that thecompressed solid block enrobing the plate is positioned in the path ofthe flush water. Again, the dimensions and in particular the length ofthe stalk can be varied in order to meet the specific requirements of aspecific configuration of a sanitary appliance, particularly in the caseof a toilet bowl, the distance from the top of the rim downwardly intothe interior of the toilet bowl, or in the case of a cistern or tank,the distance from the top of the rim of the tank or cistern downwardlysuch that the plate intersects or is beneath the waterline of the waterpresent in the tank or cistern between flushes. For example, when usedas an ITB device, in toilets typically found in use in North America,the interior sloping walls of the toilet bowl are typically of a smallerand a more circular radius, thereby providing a “shallower” distancebetween the top of the rim of the toilet bowl, and the sump or wateroutlet at the bottom of the toilet bowl. In such a circumstance, ashorter stalk length is typically adequate in order to ensure that thecompressed solid block is placed within the path of the flush water. InEuropean toilets, typically, the configuration of the toilet bowl andits sloping walls are usually in the form of a more frusto-conicalconfiguration, thus providing a “deeper” toilet bowl as measured fromthe rim to the top level of the water in the sump. In suchconfiguration, frequently, a longer stalk length then would be requiredfor a North American toilet is typically preferred. Of course, differentconfigurations of other toilet bowls are contemplated as well.

The hanger of the invention also requires a plate which is adapted to beembedded and/or enrobed within the compressed solid block composition.The plate itself is at the end distal to the hook end of the hanger andtypically is integrally formed with the stalk, or where a stalk is notprovided, with the hook end of the hanger. The plate itself may beessentially of any useful configuration, but desirably, the plate isdimensioned such that it is completely encased by the compressed solidblock composition. Conveniently, the plate has a geometry which issymmetrical about the longitudinal center line or axis of the stalkand/or hook and depends directly from the stalk where present or fromthe end of the hook end of the hanger. Conveniently, the plate isgenerally of a flat, planar configuration, and has a uniform thicknessacross its surface. However, it is also contemplated that the plate mayinclude regions of diminishing thickness i.e. such as tapered sectionsor margins at or near the boundaries of the plate.

The plate itself need not necessarily be limited to a generally planar,and generally two-dimensional configuration, but may include elements orsections which extend outwardly from the top and/or bottom surfaces ofthe plate, such as in the form of one or more pegs, studs, pins, fins,rods, loops or the like which might be useful in providing furtherphysical support between the plate, and the compressed solid blockcomposition enrobing it. Alternately, the plate may include one or moreperforations passing therethrough whereby, upon compression adjacentportions of the solid block composition meet and pass through one ormore perforations which may be provided within the plate.

The plate itself may be of any configuration and when in a planar formcan be square, rectangular, triangular, polygonal, ellipsoid, circular,oblate, or for that matter any configuration which may be embeddedwithin the interior of the compressed solid block. Alternately, theplate can may be one or more elements such as rods or tubes, whichdepend from and extend outwardly from the stalk. While the thickness ofthe plate may vary, preferably it is between 0.05-3 mm thick, preferablybetween 0.1 and 2 mm thick, and most preferably between 0.25 and 1.5 mmthick. The thickness of the plate may vary across its surface, and incertain embodiments the thickness of the plate decreases across itsdimensions with the thickest portion of the plate being near itsgeometric center, and the thinnest parts of the plate being one or moreof the margins or peripheral sections of the plate. Such may be used toform a plate of tapering dimensions. Preferably however the plate is ofgenerally uniform in thickness with at least 90%, preferably at least95% of its surface being of a constant thickness with a variance of notmore than +/−5%.

Alternately the plate can be of a configuration other than a planarconfiguration, e.g., the plate can may be one or more elements such asrods or tubes, which depend from and extend outwardly from the stalk.

The inventors have also unexpectedly observed that the preferredconfiguration of the plate is a generally planar plate which has slopingtop edges which are angled downwardly and form an obtuse angle with thecenter line (or center-axis) of the stalk or hook of the hanger, asmeasured from the points from which the edges of plate intersect thestalk or hook end. The downwardly sloping edges may be linear orstraight-edged, or arcuate. The inventors have found that downwardlysloping edges are advantageous in resisting pooling of water, and permitfor the runoff of water during the service life of the cageless lavatorydevices when the compressed solid blocks may have sufficiently eroded toexpose part of the plate from within the interior of the said blocks.

Surprisingly, the inventors have found that the best configuration forthe plate is indeed a generally planar plate having a generally uniformthickness across its surface. The dimensions of the plate should be suchthat when considering the cross-sectional area of the plate with that ofthe cross-sectional laminar layer of the block within which it ispositioned, the percent coverage of the plate area to the laminarcompressed solid block area should be not more than about 90%, morepreferably the ratio is between about 10% and 90%, more preferablybetween about 20% and 80% of the surface area of the laminar layer orplane of the compressed solid block composition within which the platelies.

The inventors have also surprisingly found that while many plateconfigurations are possible, the longest service life of the cagelesslavatory devices were observed with generally planar plates which weresubstantially embedded and enrobed within the interior of the compressedsolid block composition. The compressed solid blocks do not require theuse of an adhesive substance or material intermediate the plate and thecompressed solid block in order to retain the compressed solid block onthe faces of the plate. While not wishing to be bound by the following,it was theorized that when used as an ITB type device, during repeatedflushes of water coming into contact with the upper surface of thecompressed solid block, viz, the region from which the stalk or hook endextends, minimal cracking or delamination of the regions of the blockwhich had been joined together by the compression of the solid block wasobserved. This reduction of delamination or otherwise observed assplitting of the block in this region ensured the longer term retentionof the compressed solid block composition upon the plate, and therebythe improved duration of the service life of the cageless lavatorydevice used in conjunction with the sanitary appliance. Surprisingly, itwas observed that when perforations, including large diameter circles orother discontinuities were present passing through the plate, thecompressed solid blocks mounted upon the plates were observed to oftenprematurely fail. Again, and while I am not wishing to be bound by thefollowing, it is believed that the formation of miniscule channels inthe region of the compressed solid block which had been laminated mayhave formed during repeated flush cycles, and these channels passinginto the interior of the block formed cavities and/or otherwise softenthe interior of the compressed solid block in the region of suchdiscontinuities in the plate, thereby mechanically softening the blockand weakening its hold upon the plate. Similarly, it is also observedthat when the plate had a more three-dimensional shape, that is to sayincluded elements such as studs, or pins extending outwardly from one ormore faces of the plate, that again, premature failure of the compressedsolid block compositions was observed. Again, it is believed that asimilar phenomenon also occurred, namely in the formation ofmicrochannels in the region of the lamination of portions of the blockwere formed, and provided for the flow of flush water into the interiorof the block and to the region of the plate and particularly to theregions surrounding the extended studs or pins. Again, this was believedto be responsible for premature softening of the interior of thecompressed solid block, and its premature failure.

Thus, in particularly preferred embodiments, the plate configuration isabsent any perforations, as well as being absent of any elements orprotrusions extending outwardly from one or more faces of the plate.

In a preferred embodiment the a cageless lavatory device comprises ahanger having a standoff section and a compressed solid block comprisingone or more chemical constituents for use with a sanitary appliance,particularly a toilet. According to this embodiment, the hanger is anarticle which comprises at one end, a hook end which is adapted to orconfigured to suspend the hanger from a part of a sanitary appliance asdescribed above. The hanger is preferably configured so to permit itsuse either as an ITB device or as an ITC device. The hanger alsoincludes a plate, also as described above, which is adapted to beembedded within the compressed solid block composition, and a standoffsection or standoff element which is intermediate the hook end and theplate of the hanger. While the hook end may be integrally formed and beproximate to the plate, quite frequently the hanger includes anintermediate stalk connecting the hook end with the plate. Convenientlythe stalk includes an integral section or a portion of the stalk isformed to provide a standoff section, or alternately an element separatefrom the stalk but affixable thereto may be provided as a standoffelement. The standoff element may conveniently be a formed section ofthe hanger or stalk such that the standoff element is an integralsection of the hook or stalk. Alternately the standoff element may be adiscrete element or discrete part which may be affixed to a part of thehanger, preferably to a part of the stalk. The hanger standoff elementmay positioned or located anywhere between the hook end and the platebut advantageously is positioned or located proximate to the plate,preferably with respect to the total length of the hanger as measuredfrom the end of the hook end, to the end or bottom of the plate, thestandoff element is within the lower half of this length and proximateto the plate. Preferably the standoff element is within the lower 40% ofthe distance, more preferably is within the lower 33% of this distance.In particularly preferred embodiments the standoff element is at aposition adjacent to the compressed solid block encasing or enrobing theplate.

Desirably, when present the standoff element is suitably dimensionedsuch that it is adapted to extend from the stalk or other part of thehanger in a direction rearwardly of the stalk, that is to say, in thedirection which is coincident with the direction of the hook endrelative to the stalk. Thus, when the cageless lavatory device ismounted on the rim of a toilet bowl or on the rim of a toilet cistern ortoilet tank, the standoff element extends in generally the samedirection as the hook end. Desirably this direction is also generallyperpendicular, viz., 90°, +/−15° relative to the plane defined by theplate. The standoff element has a height dimension at which is forms apeak point which is the maximum distance from which it extends from thestalk. Desirably the height of the standoff element is such that whenthe cageless lavatory device is initially installed in a sanitaryappliance, the height of the standoff element is sufficient to impedesome physical contact between the compressed solid block and a sidewallor other part of a sanitary appliance adjacent to the said block, and/orwhen the said block is partially eroded due to dissolution or othercause the height of the standoff element is sufficiently great such thatthe peak point of the standoff element contacts the sidewall or otherpart of the sanitary device and acts to lift the compressed solid blocksuch that a gap is formed between the said sidewall or other part andthe solid block. In certain embodiments, such occurs when less than 50%of the total mass of the compressed solid lock, preferably when lessthan 65% of the compressed solid block is eroded or dissolved. Theformation of such a gap, particularly prior to the substantial erosionof the compressed solid block is surprisingly advantageous from severaltechnical perspectives. First, the formation of such a gap permits forthe composition of the compressed solid block to be out of contact witha wet sidewall between flush cycles when the cageless lavatory device isused in a toilet bowl. Such improves the service life of the compressedsolid block. Second, when the compressed solid block includes asurfactant constituent, and is spaced-apart from the sidewall of atoilet bowl, during the flush cycle improved foam formation is observedto occur. While not wishing to be bound by the following the inventorsbelieve that the gap between the surface of the compressed solid blocksuspended on the hanger and the adjacent sidewall of the toilet bowlprovides for some cavitation and air entrainment within this gap spaceduring the flushing operation. Such is believed to improve the formationof bubbles and a more visible foam. Preferably the gap between the gapbetween the surface of the compressed solid block suspended on thehanger and the adjacent sidewall of the sanitary appliance should be inthe range of from 0.2-3 mm at the closest point between the blocksurface and the adjacent sidewall.

While it is understood that various configurations and geometries of thecompressed block compositions, as well as various configurations andgeometries of the hanger and standoff element are possible, it isnonetheless preferred that the relative dimensions of these elements issuch that when the cageless lavatory device is formed but has not beenput into service, when the said device is laid upon a flat horizontalsurface, the standoff element has a sufficient height such that the peakpoint is sufficient to raise at least a part of the rearward face of thecompressed solid block from contacting the horizontal surface.Preferably as well, after the cageless lavatory device is put intoservice and installed in a sanitary appliance, preferably a toilet bowland at least 50% of the mass is eroded, desirably the height of thestandoff element is sufficient that the peak point contacts the surfaceof the sanitary appliance adjacent to the compressed solid block and issufficient to cause a gap of at least 0.2 mm, preferably a gap ofbetween 0.2 and 3 mm between the closest point between the block surfaceand the adjacent sidewall.

The hanger, whether a single unitary piece or assembled from a compositeof discrete pieces or elements may be formed from any of a variety ofmaterials which can be used for the purpose described herein. Exemplaryand preferred materials include metals including wires or rods which arebendable and are preferably coated with flexible non-metallic materialsuch as a flexible polymer, a paint or a sheath, as well as one or moresynthetic polymers which are preferred. Preferably the hanger may beformed of any of a number of thermosettable or thermoform able syntheticpolymers such as are widely used in casting or injection molding.Exemplary synthetic polymers such as polyamides, polyolefins (e.g.,polypropylene, polyethylene) as well as polyalkyleneterephalates (i.e.,polyethylene terephthalate, polybutylene terephthalate), polystyrenes,polysulfones, polycarbonates as well as copolymers formed from monomersof one or more of the foregoing being several nonlimiting examples ofuseful synthetic polymers. Preferably the material of construction is atleast somewhat flexible. As to the material of construction of thehanger, the only criteria being that the selected materials used tofabricate the hanger is not deleteriously affected by the chemicalconstituents of the compressed solid block composition with which partof the hanger, viz., the plate and possibly part of the stalk. contacts.

The cageless lavatory devices according to the invention necessarilyalso comprise a compressed solid block comprising at least one or morechemical constituents such that when the block is immersed, rinsed orwashed with water, said chemical constituents are eluted or dissolvedinto said water and forms a treatment composition which is useful intreating a sanitary appliance, and particularly a toilet tank or cisternor a toilet bowl.

As chemical constituents the compressed solid block may include anyknown art cleaning agents or cleaning constituents known to those ofordinary skill in the relevant art, and without limitation include oneor more detersive surfactants selected from anionic, cationic, nonionicas well as amphoteric or zwitterionic surfactants. Certain detersivesurfactants may also provide a dual role in providing detergency as wellas a disinfecting effect, viz, certain cationic surfactants, which aredescribed hereinafter as a disinfecting agent. These one or morecleaning agents or cleaning constituents may be used with or withoutother constituents being present in the compressed solid blocks of theinvention.

The solid block composition of the invention desirably comprises asurfactant constituent which may be one or more detersive surfactants.Exemplary useful surfactants include anionic, nonionic, cationic,amphoteric, and zwitterionic surfactants, particularly those whosemelting points are sufficiently high, above about 110° F., preferablyabove 125° F., to permit processing according to known art techniques.However, small amounts of low melting point surfactants and even liquidsurfactants may be used in providing the surfactant constituent.

Exemplary useful anionic surfactants which may be used in the compressedsolid block composition of the invention can be broadly described as thewater-soluble salts, particularly the alkali metal salts, of organicsulfuric acid reaction products having in their molecular structure analkyl or alkaryl radical containing from about 8 to about 22 carbonatoms and a radical selected from the group consisting of sulfonic acidand sulfuric acid ester radicals. (Included in the term alkyl is thealkyl portion of higher acyl radicals). Important examples of theanionic surfactants which can be employed in practicing the presentinvention are the sodium or potassium alkyl sulfates, especially thoseobtained by sulfating the higher alcohols (C₈-C₁₈ carbon atoms) producedby reducing the glycerides of tallow or coconut oil; sodium or potassiumalkyl benzene sulfonates, in which the alkyl group contains from about 9to about 15 carbon atoms, (the alkyl radical can be a straight orbranched aliphatic chain); paraffin sulfonate surfactants having thegeneral formula RSO₃ M, wherein R is a primary or secondary alkyl groupcontaining from about 8 to about 22 carbon atoms (preferably 10 to 18carbon atoms) and M is an alkali metal, e.g., sodium, lithium orpotassium; sodium alkyl glyceryl ether sulfonates, especially thoseethers of the higher alcohols derived from tallow and coconut oil;sodium coconut oil fatty acid monoglyceride sulfates and sulfonates;sodium or potassium salts of sulfuric acid esters of the reactionproduct of one mole of a higher fatty alcohol (e.g., tallow or coconutoil alcohols) and about 1 to 10 moles of ethylene oxide; sodium orpotassium salts of alkyl phenol ethylene oxide ether sulfates with about1 to about 10 units of ethylene oxide per molecule and in which thealkyl radicals contain from about 8 to about 12 carbon atoms; thereaction products of fatty acids esterified with isethionic acid andneutralized with sodium hydroxide where, for example, the fatty acidsare derived from coconut oil; sodium or potassium salts of fatty acidamides of a methyl tauride in which the fatty acids, for example, arederived from coconut oil and sodium or potassium β-acetoxy- orβ-acetamido-alkanesulfonates where the alkane has from 8 to 22 carbonatoms.

A preferred class of anionic surfactants are linear alkyl benzenesulfonate surfactant wherein the alkyl portion contains 8 to 16 carbonatoms, and most preferably about 11 to 13 carbon atoms. According toparticularly preferred embodiments of the invention, the solid blockcompositions necessarily include an anionic surfactant.

A further preferred class of anionic surfactants are alpha olefinsulfonates, as well as salts thereof, e.g., alkali metal salts.Preferred are C₈ through C₂₂ alpha olefin sulfonates, particularly C₁₂through C₁₈, and especially C₁₄, and C₁₆ alpha olefin sulfonates as wellas blends of two or more thereof. According to particularly preferredembodiments of the invention, the solid block compositions necessarilyinclude an alpha olefin sulfonate anionic surfactant.

The detersive surfactant constituent of the solid block composition ofthe invention may include one or more nonionic surfactants. Practicallyany hydrophobic compound having a carboxy, hydroxy, amido, or aminogroup with a free hydrogen attached to the nitrogen can be condensedwith an alkylene oxide, especially ethylene oxide or with thepolyhydration product thereof, a polyalkylene glycol, especiallypolyethylene glycol, to form a water soluble or water dispersiblenonionic surfactant compound. Further, the length of the polyethenoxyhydrophobic and hydrophilic elements may various. Exemplary nonioniccompounds include the polyoxyethylene ethers of alkyl aromatic hydroxycompounds, e.g., alkylated polyoxyethylene phenols, polyoxyethyleneethers of long chain aliphatic alcohols, the polyoxyethylene ethers ofhydrophobic propylene oxide polymers, and the higher alkyl amine oxides.

One class of useful nonionic surfactants include polyalkylene oxidecondensates of alkyl phenols. These compounds include the condensationproducts of alkyl phenols having an alkyl group containing from about 6to 12 carbon atoms in either a straight chain or branched chainconfiguration with an alkylene oxide, especially an ethylene oxide, theethylene oxide being present in an amount equal to 5 to 25 moles ofethylene oxide per mole of alkyl phenol. The alkyl substituent in suchcompounds can be derived, for example, from polymerized propylene,diisobutylene and the like. Examples of compounds of this type includenonyl phenol condensed with about 9.5 moles of ethylene oxide per moleof nonyl phenol; dodecylphenol condensed with about 12 moles of ethyleneoxide per mole of phenol; dinonyl phenol condensed with about 15 molesof ethylene oxide per mole of phenol and diisooctyl phenol condensedwith about 15 moles of ethylene oxide per mole of phenol.

A further class of useful nonionic surfactants include the condensationproducts of aliphatic alcohols with from about 1 to about 60 moles of analkylene oxide, especially an ethylene oxide. The alkyl chain of thealiphatic alcohol can either be straight or branched, primary orsecondary, and generally contains from about 8 to about 22 carbon atoms.Examples of such ethoxylated alcohols include the condensation productof myristyl alcohol condensed with about 10 moles of ethylene oxide permole of alcohol and the condensation product of about 9 moles ofethylene oxide with coconut alcohol (a mixture of fatty alcohols withalkyl chains varying in length from about 10 to 14 carbon atoms). Otherexamples are those C₆-C₁₁ straight-chain alcohols which are ethoxylatedwith from about 3 to about 6 moles of ethylene oxide. Their derivationis well known in the art. Examples include Alfonic® 810-4.5, which isdescribed in product literature from Sasol as a C₈-C₁₀ straight-chainalcohol having an average molecular weight of 356, an ethylene oxidecontent of about 4.85 moles (about 60 wt. %), and an HLB of about 12;Alfonic® 810-2, which is described in product literature as a C₈-C₁₀straight-chain alcohols having an average molecular weight of 242, anethylene oxide content of about 2.1 moles (about 40 wt. %), and an HLBof about 12; and Alfonic® 610-3.5, which is described in productliterature as having an average molecular weight of 276, an ethyleneoxide content of about 3.1 moles (about 50 wt. %), and an HLB of 10.Other examples of alcohol ethoxylates are C₁₀ oxo-alcohol ethoxylatesavailable from BASF under the Lutensol® ON tradename. They are availablein grades containing from about 3 to about 11 moles of ethylene oxide(available under the names Lutensol® ON 30; Lutensol® ON 50; Lutensol®ON 60; Lutensol® ON 65; Lutensol® ON 66; Lutensol® ON 70; Lutensol® ON80; and Lutensol®ON 110). Other examples of ethoxylated alcohols includethe Neodol® 91 series non-ionic surfactants available from ShellChemical Company which are described as C₉-C₁₁ ethoxylated alcohols. TheNeodol® 91 series non-ionic surfactants of interest include Neodol®91-2.5, Neodol® 91-6, and Neodol® 91-8. Neodol® 91-2.5 has beendescribed as having about 2.5 ethoxy groups per molecule; Neodol 91-6has been described as having about 6 ethoxy groups per molecule; andNeodol 91-8 has been described as having about 8 ethoxy groups permolecule. Further examples of ethoxylated alcohols include theRhodasurf® DA series non-ionic surfactants available from Rhodia whichare described to be branched isodecyl alcohol ethoxylates. Rhodasurf®DA-530 has been described as having 4 moles of ethoxylation and an HLBof 10.5; Rhodasurf® DA-630 has been described as having 6 moles ofethoxylation with an HLB of 12.5; and Rhodasurf® DA-639 is a 90%solution of DA-630. Further examples of ethoxylated alcohols includethose from Tomah Products (Milton, Wis.) under the Tomadol® tradenamewith the formula RO(CH₂CH₂O)_(n)H where R is the primary linear alcoholand n is the total number of moles of ethylene oxide. The ethoxylatedalcohol series from Tomah include 91-2.5; 91-6; 91-8—where R is linearC₉/C₁₀/C₁₁ and n is 2.5, 6, or 8; 1-3; 1-5; 1-7; 1-73B; 1-9; where R islinear C₁₁ and n is 3, 5, 7 or 9; 23-1; 23-3; 23-5; 23-6.5—where R islinear C₁₂/C₁₃ and n is 1, 3, 5, or 6.5; 25-3; 25-7; 25-9; 25-12—where Ris linear C₁₂/C₁₃/C₁₄/C₁₅ and n is 3, 7, 9, or 12; and 45-7; 45-13—whereR is linear C₁₄/C₁₅ and n is 7 or 13.

A further class of useful nonionic surfactants include primary andsecondary linear and branched alcohol ethoxylates, such as those basedon C₆-C₁₈ alcohols which further include an average of from 2 to 80moles of ethoxylation per mol of alcohol. These examples include theGenapol® UD (ex. Clariant, Muttenz, Switzerland) described under thetradenames Genapol® UD 030, C₁₁-oxo-alcohol polyglycol ether with 3 EO;Genapol® UD, 050 C₁₁-oxo-alcohol polyglycol ether with 5 EO; Genapol® UD070, C₁₁-oxo-alcohol polyglycol ether with 7 EO; Genapol® UD 080,C₁₁-oxo-alcohol polyglycol ether with 8 EO; Genapol® UD 088,C₁₁-oxo-alcohol polyglycol ether with 8 EO; and Genapol® UD 110,C₁₁-oxo-alcohol polyglycol ether with 11 EO.

Exemplary useful nonionic surfactants include the condensation productsof a secondary aliphatic alcohols containing 8 to 18 carbon atoms in astraight or branched chain configuration condensed with 5 to 30 moles ofethylene oxide. Examples of commercially available nonionic detergentsof the foregoing type are those presently commercially available underthe trade name of Tergitol® such as Tergitol 15-S-12 which is describedas being C₁₁-C₁₅ secondary alkanol condensed with 9 ethylene oxideunits, or Tergitol 15-S-9 which is described as being C₁₁-C₁₅ secondaryalkanol condensed with 12 ethylene oxide units per molecule.

A further class of useful nonionic surfactants include those surfactantshaving a formula:RO(CH₂CH₂O)_(n)Hwherein;R is a mixture of linear, even carbon-number hydrocarbon chains rangingfrom C₁₂H₂₅ to C₁₆H₃₃ and n represents the number of ethoxy repeatingunits and is a number of from about 1 to about 12.

Surfactants of this formula are presently marketed under the Genapol®tradename (ex. Clariant), which surfactants include the “26-L” series ofthe general formula RO(CH₂CH₂O)_(n)H wherein R is a mixture of linear,even carbon-number hydrocarbon chains ranging from C₁₂H₂₅ to C₁₆H₃₃ andn represents the number of repeating units and is a number of from 1 toabout 12, such as 26-L-1, 26-L-1.6, 26-L-2, 26-L-3, 26-L-5, 26-L-45,26-L-50, 26-L-60, 26-L-60N, 26-L-75, 26-L-80, 26-L-98N, and the 24-Lseries, derived from synthetic sources and typically contain about 55%C₁₂ and 45% C₁₄ alcohols, such as 24-L-3, 24-L-45, 24-L-50, 24-L-60,24-L-60N, 24-L-75, 24-L-92, and 24-L-98N, all sold under the Genapol®tradename.

Further useful non-ionic surfactants which may be used in the inventivecompositions include those presently marketed under the trade namePluronics® (ex. BASF). The compounds are formed by condensing ethyleneoxide with a hydrophobic base formed by the condensation of propyleneoxide with propylene glycol. The molecular weight of the hydrophobicportion of the molecule is of the order of 950 to 4,000 and preferably200 to 2,500. The addition of polyoxyethylene radicals of thehydrophobic portion tends to increase the solubility of the molecule asa whole so as to make the surfactant water-soluble. The molecular weightof the block polymers varies from 1,000 to 15,000 and the polyethyleneoxide content may comprise 20% to 80% by weight. Preferably, thesesurfactants are in liquid form and particularly satisfactory surfactantsare available as those marketed as Pluronics® L62 and Pluronics® L64.

Further nonionic surfactants which may be included in the inventivecompositions include alkoxylated alkanolamides, preferably C₈-C₂₄ alkyldi(C₂-C₃ alkanol amides), as represented by the following formula:R₅—CO—NH—R₆—OHwherein R₅ is a branched or straight chain C₈-C₂₄ alkyl radical,preferably a C₁₀-C₁₆ alkyl radical and more preferably a C₁₂-C₁₄ alkylradical, and R₆ is a C₁-C₄ alkyl radical, preferably an ethyl radical.

According to certain particularly preferred embodiments the detersivesurfactant constituent necessarily comprises a nonionic surfactant basedon a linear primary alcohol ethoxylate particularly wherein the alkylportion is a C₈ to C₁₆, but particularly a C₉ to C₁₁ alkyl group, andhaving an average of between about 6 to about 8 moles of ethoxylation.

One further useful class of nonionic surfactants include those in whichthe major portion of the molecule is made up of block polymeric C₂-C₄alkylene oxides, with alkylene oxide blocks containing C₃ to C₄ alkyleneoxides. Such nonionic surfactants, while preferably built up from analkylene oxide chain starting group, can have as a starting nucleusalmost any active hydrogen containing group including, withoutlimitation, amides, phenols, and secondary alcohols.

One group of nonionic surfactants containing the characteristic alkyleneoxide blocks are those which may be generally represented by the formula(A):HO-(EO)_(x)(PO)_(y)(EO)_(z)—H  (A)where EO represents ethylene oxide,

-   -   PO represents propylene oxide,    -   y equals at least 15,    -   (EO)_(x+z) equals 20 to 50% of the total weight of said        compounds, and, the total molecular weight is preferably in the        range of about 2000 to 15,000.

Another group of nonionic surfactants appropriate for use in the newcompositions can be represented by the formula (B).R-(EO,PO)_(a)(EO,PO)_(b)—H  (B)wherein R is an alkyl, aryl or aralkyl group,

-   -   the alkoxy group contains 1 to 20 carbon atoms, the weight        percent of EO is within the range of 0 to 45% in one of the        blocks a, b, and within the range of 60 to 100% in the other of        the blocks a, b, and the total number of moles of combined EO        and PO is in the range of 6 to 125 moles, with 1 to 50 moles in        the PO rich block and 5 to 100 moles in the EO rich block.

Further nonionic surfactants which in general are encompassed by FormulaB include butoxy derivatives of propylene oxide/ethylene oxide blockpolymers having molecular weights within the range of about 2000-5000.

Still further useful nonionic surfactants containing polymeric butoxy(BO) groups can be represented by formula (C) as follows:RO—(BO)_(n)(EO)_(x)—H  (C)wherein R is an alkyl group containing 1 to 20 carbon atoms,

-   -   n is about 15 and x is about 15.

Also useful as the nonionic block copolymer surfactants which alsoinclude polymeric butoxy groups are those which may be represented bythe following formula (D):HO-(EO)_(x)(BO)_(n)(EO)_(y)—H  (D)wherein n is about 15,

-   -   x is about 15 and    -   y is about 15.

Still further useful nonionic block copolymer surfactants includeethoxylated derivatives of propoxylated ethylene diamine, which may berepresented by the following formula:

where (EO) represents ethoxy,

(PO) represents propoxy,

the amount of (PO)_(x) is such as to provide a molecular weight prior toethoxylation of about 300 to 7500, and the amount of (EO)_(y) is such asto provide about 20% to 90% of the total weight of said compound.

Further useful nonionic surfactants include nonionic amine oxideconstituent. Exemplary amine oxides include:

A) Alkyl di (lower alkyl) amine oxides in which the alkyl group hasabout 10-20, and preferably 12-16 carbon atoms, and can be straight orbranched chain, saturated or unsaturated. The lower alkyl groups includebetween 1 and 7 carbon atoms. Examples include lauryl dimethyl amineoxide, myristyl dimethyl amine oxide, and those in which the alkyl groupis a mixture of different amine oxide, dimethyl cocoamine oxide,dimethyl (hydrogenated tallow) amine oxide, and myristyl/palmityldimethyl amine oxide;

B) Alkyl di (hydroxy lower alkyl) amine oxides in which the alkyl grouphas about 10-20, and preferably 12-16 carbon atoms, and can be straightor branched chain, saturated or unsaturated. Examples arebis(2-hydroxyethyl)cocoamine oxide, bis(2-hydroxyethyl) tallowamineoxide; and bis(2-hydroxyethyl)stearylamine oxide;

C) Alkylamidopropyl di(lower alkyl) amine oxides in which the alkylgroup has about 10-20, and preferably 12-16 carbon atoms, and can bestraight or branched chain, saturated or unsaturated. Examples arecocoamidopropyl dimethyl amine oxide and tallowamidopropyl dimethylamine oxide; and

D) Alkylmorpholine oxides in which the alkyl group has about 10-20, andpreferably 12-16 carbon atoms, and can be straight or branched chain,saturated or unsaturated.

Preferably the amine oxide constituent is an alkyl di (lower alkyl)amine oxide as denoted above and which may be represented by thefollowing structure:

wherein each:

R₁ is a straight chained C₁-C₄ alkyl group, preferably both R₁ aremethyl groups; and,

R₂ is a straight chained C₈-C₁₈ alkyl group, preferably is C₁₀-C₁₄ alkylgroup, most preferably is a C₁₂ alkyl group.

Each of the alkyl groups may be linear or branched, but most preferablyare linear. Most preferably the amine oxide constituent is lauryldimethyl amine oxide. Technical grade mixtures of two or more amineoxides may be used, wherein amine oxides of varying chains of the R₂group are present. Preferably, the amine oxides used in the presentinvention include R₂ groups which comprise at least 50% wt., preferablyat least 60% wt. of C₁₂ alkyl groups and at least 25% wt. of C₁₄ alkylgroups, with not more than 15% wt. of C₁₆, C₁₈ or higher alkyl groups asthe R₂ group.

Still further exemplary useful nonionic surfactants which may be usedinclude certain alkanolamides including monoethanolamides anddiethanolamides, particularly fatty monoalkanolamides and fattydialkanolamides.

A cationic surfactant may be incorporated as a germicide or as adetersive surfactant in the solid block composition of the presentinvention, particularly wherein a bleach constituent is absent from thesolid block composition. Cationic surfactants are per se, well known,and exemplary useful cationic surfactants may be one or more of thosedescribed for example in McCutcheon's Functional Materials, Vol. 2,1998; Kirk-Othmer, Encyclopedia of Chemical Technology, 4th Ed., Vol.23, pp. 481-541 (1997), the contents of which are herein incorporated byreference. These are also described in the respective productspecifications and literature available from the suppliers of thesecationic surfactants.

Examples of preferred cationic surfactant compositions useful in thepractice of the instant invention are those which provide a germicidaleffect to the concentrate compositions, and especially preferred arequaternary ammonium compounds and salts thereof, which may becharacterized by the general structural formula:

where at least one of R₁, R₂, R₃ and R₄ is a alkyl, aryl or alkylarylsubstituent of from 6 to 26 carbon atoms, and the entire cation portionof the molecule has a molecular weight of at least 165. The alkylsubstituents may be long-chain alkyl, long-chain alkoxyaryl, long-chainalkylaryl, halogen-substituted long-chain alkylaryl, long-chainalkylphenoxyalkyl, arylalkyl, etc. The remaining substituents on thenitrogen atoms other than the abovementioned alkyl substituents arehydrocarbons usually containing no more than 12 carbon atoms. Thesubstituents R₁, R₂, R₃ and R₄ may be straight-chained or may bebranched, but are preferably straight-chained, and may include one ormore amide, ether or ester linkages. The counterion X may be anysalt-forming anion which permits water solubility of the quaternaryammonium complex.

Exemplary quaternary ammonium salts within the above description includethe alkyl ammonium halides such as cetyl trimethyl ammonium bromide,alkyl aryl ammonium halides such as octadecyl dimethyl benzyl ammoniumbromide, N-alkyl pyridinium halides such as N-cetyl pyridinium bromide,and the like. Other suitable types of quaternary ammonium salts includethose in which the molecule contains either amide, ether or esterlinkages such as octyl phenoxy ethoxy ethyl dimethyl benzyl ammoniumchloride, N-(laurylcocoaminoformylmethyl)-pyridinium chloride, and thelike. Other very effective types of quaternary ammonium compounds whichare useful as germicides include those in which the hydrophobic radicalis characterized by a substituted aromatic nucleus as in the case oflauryloxyphenyltrimethyl ammonium chloride, cetylaminophenyltrimethylammonium methosulfate, dodecylphenyltrimethyl ammonium methosulfate,dodecylbenzyltrimethyl ammonium chloride, chlorinateddodecylbenzyltrimethyl ammonium chloride, and the like.

Preferred quaternary ammonium compounds which act as germicides andwhich are be found useful in the practice of the present inventioninclude those which have the structural formula:

wherein R₂ and R₃ are the same or different C₈-C₁₂alkyl, or R₂ isC₁₂₋₁₆alkyl, C₈₋₁₈alkylethoxy, C₈₋₁₈alkylphenolethoxy and R₃ is benzyl,and X is a halide, for example chloride, bromide or iodide, or is amethosulfate anion. The alkyl groups recited in R₂ and R₃ may bestraight-chained or branched, but are preferably substantially linear.

Particularly useful quaternary germicides include compositions whichinclude a single quaternary compound, as well as mixtures of two or moredifferent quaternary compounds. Such useful quaternary compounds areavailable under the BARDAC®, BARQUAT®, HYAMINE®, LONZABAC®, and ONYXIDE®trademarks, which are more fully described in, for example, McCutcheon'sFunctional Materials (Vol. 2), North American Edition, 1998, as well asthe respective product literature from the suppliers identified below.For example, BARDAC® 205M is described to be a liquid containing alkyldimethyl benzyl ammonium chloride, octyl decyl dimethyl ammoniumchloride; didecyl dimethyl ammonium chloride, and dioctyl dimethylammonium chloride (50% active) (also available as 80% active (BARDAC®208M)); described generally in McCutcheon's as a combination of alkyldimethyl benzyl ammonium chloride and dialkyl dimethyl ammoniumchloride); BARDAC® 2050 is described to be a combination of octyl decyldimethyl ammonium chloride/didecyl dimethyl ammonium chloride, anddioctyl dimethyl ammonium chloride (50% active) (also available as 80%active (BARDAC® 2080)); BARDAC® 2250 is described to be didecyl dimethylammonium chloride (50% active); BARDAC® LF (or BARDAC® LF-80), describedas being based on dioctyl dimethyl ammonium chloride (BARQUAT® MB-50,MX-50, OJ-50 (each 50% liquid) and MB-80 or MX-80 (each 80% liquid) areeach described as an alkyl dimethyl benzyl ammonium chloride; BARDAC®4250 and BARQUAT® 4250Z (each 50% active) or BARQUAT® 4280 and BARQUAT4280Z (each 80% active) are each described as alkyl dimethyl benzylammonium chloride/alkyl dimethyl ethyl benzyl ammonium chloride. Also,HYAMINE® 1622, described as diisobutyl phenoxy ethoxy ethyl dimethylbenzyl ammonium chloride (50% solution); HYAMINE® 3500 (50% actives),described as alkyl dimethyl benzyl ammonium chloride (also available as80% active (HYAMINE® 3500-80)); and HYMAINE® 2389 described as beingbased on methyldodecylbenzyl ammonium chloride and/ormethyldodecylxylene-bis-trimethyl ammonium chloride. (BARDAC®, BARQUAT®and HYAMINE® are presently commercially available from Lonza, Inc.,Fairlawn, N.J.). BTC® 50 NF (or BTC® 65 NF) is described to be alkyldimethyl benzyl ammonium chloride (50% active); BTC® 99 is described asdidecyl dimethyl ammonium chloride (50% active); BTC® 776 is describedto be myrisalkonium chloride (50% active); BTC® 818 is described asbeing octyl decyl dimethyl ammonium chloride, didecyl dimethyl ammoniumchloride, and dioctyl dimethyl ammonium chloride (50% active) (availablealso as 80% active (BTC® 818-80%)); BTC® 824 and BTC® 835 are eachdescribed as being of alkyl dimethyl benzyl ammonium chloride (each 50%active); BTC® 885 is described as a combination of BTC® 835 and BTC® 818(50% active) (available also as 80% active (BTC® 888)); BTC® 1010 isdescribed as didecyl dimethyl ammonium chloride (50% active) (alsoavailable as 80% active (BTC® 1010-80)); BTC® 2125 (or BTC® 2125 M) isdescribed as alkyl dimethyl benzyl ammonium chloride and alkyl dimethylethylbenzyl ammonium chloride (each 50% active) (also available as 80%active (BTC® 2125 80 or BTC® 2125 M)); BTC® 2565 is described as alkyldimethyl benzyl ammonium chlorides (50% active) (also available as 80%active (BTC® 2568)); BTC® 8248 (or BTC® 8358) is described as alkyldimethyl benzyl ammonium chloride (80% active) (also available as 90%active (BTC® 8249)); ONYXIDE® 3300 is described as n-alkyl dimethylbenzyl ammonium saccharinate (95% active). (BTC® and ONYXIDE® arepresently commercially available from Stepan Company, Northfield, Ill.)Polymeric quaternary ammonium salts based on these monomeric structuresare also considered desirable for the present invention. One example isPOLYQUAT®, described as being a 2-butenyldimethyl ammonium chloridepolymer.

Preferred quaternary germicides used in the compressed solid blockcompositions are those which are supplied in a solid or powdered form,as such greatly facilitates the manufacture of the compressed solidblock compositions.

When present in a compressed solid block composition, it is preferredthat the germicidal cationic surfactant(s) are present in amounts so todispense at least about 200 parts per million (ppm) in the water flushedinto the sanitary appliance, e.g., toilet bowl, or into the waterretained in the sanitary appliance at the conclusion of the flush cycle.

Further detersive surfactants which may be included are amphoteric andzwitterionic surfactants which provide a detersive effect. Exemplaryuseful amphoteric surfactants include alkylbetaines, particularly thosewhich may be represented by the following structural formula:RN⁺(CH₃)₂CH₂COO⁻wherein R is a straight or branched hydrocarbon chain which may includean aryl moiety, but is preferably a straight hydrocarbon chaincontaining from about 6 to 30 carbon atoms. Further exemplary usefulamphoteric surfactants include amidoalkylbetaines, such asamidopropylbetaines which may be represented by the following structuralformula:RCONHCH₂CH₂CH₂N⁺(CH₃)₂CH₂COO⁻wherein R is a straight or branched hydrocarbon chain which may includean aryl moiety, but is preferably a straight hydrocarbon chaincontaining from about 6 to 30 carbon atoms.

As noted above, preferred detersive surfactants are those which exhibita melting points above about 110° F., preferably above 125° F., in orderto permit convenient processing according to known art techniques.Nonetheless small amounts of low melting point surfactants, i.e., thoseexhibiting melting points below about 110° F. and even liquidsurfactants may be used in providing the surfactant constituent of thesolid block composition.

As the performance requirements of the compressed solid blocks maydiffer according to their use as either an ITB or as an ITC block, theamounts of the constituents present in the block may vary as welldepending upon the final intended use of the treatment block.

When intended for use as an ITB block, the detersive surfactantconstituent may be present in any effective amount and generallycomprises up to about 90% wt. of the total weight of the solid blockcomposition, and the resultant treatment block formed therefrom.Preferably the detersive surfactant constituent comprises about 20-90%wt., more preferably 35-80% wt. of the solid block composition, and whenused as an ITB block the detersive surfactant constituent mostpreferably comprises about 50-75% wt. of the solid block composition,and the resultant treatment block formed therefrom. When intended foruse as an ITC block, the detersive surfactant constituent may be presentin any effective amount and generally comprises up to about 60% wt. ofthe total weight of the solid block composition, and the resultanttreatment block formed therefrom. Preferably the detersive surfactantconstituent comprises about 10-55% wt., more preferably 20-50% wt. ofthe solid block composition, and the resultant treatment block formedtherefrom.

In particularly preferred embodiments the compressed solid blocks of theinvention necessarily comprise at least one surfactant, preferably atleast one anionic surfactant.

Further exemplary chemical constituents may be one or more sanitizingagents or germicides which may be present with our without otherconstituents being present in the compressed solid blocks of thecageless lavatory devices.

The sanitizing agent can be any sanitizing composition known to those ofordinary skill in the relevant art, and without limitation exemplarysanitizing compositions include materials containing alkylhalohydantoins, alkali metal haloisocyanurates, bleach, essential oils,non-quaternary ammonium based germicidal compounds as well as quaternaryammonium germicidal compounds.

By way of non-limiting example, exemplary a bleach constituent. Thebleach constituent is relatively inert in the dry state but, which oncontact with water, releases oxygen, hypohalite or a halogen especiallychlorine. Representative examples of typical oxygen-release bleachingagents, suitable for incorporation in the solid block compositioninclude the alkali metal perborates, e.g., sodium perborate, and alkalimetal monopersulfates, e.g., sodium monopersulfates, potassiummonopersulfate, alkali metal monoperphosphates, e.g., disodiummonoperphosphate and dipotassium monoperphosphate, as well as otherconventional bleaching agents capable of liberating hypohalite, e.g.,hypochlorite and/or hypobromite, include heterocyclic N-bromo- andN-chloro-cyanurates such as trichloroisocyanuric and tribromoiscyanuricacid, dibromocyanuric acid, dichlorocyanuric acid,N-monobromo-N-mono-chlorocyanuric acid andN-monobromo-N,N-dichlorocyanuric acid, as well as the salts thereof withwater solubilizing cations such as potassium and sodium, e.g., sodiumN-monobromo-N-monochlorocyanurate, potassium dichlorocyanurate, sodiumdichlorocyanurate, as well as other N-bromo and N-chloro-imides, such asN-brominated and N-chlorinated succinimide, malonimide, phthalimide andnaphthalimide. Also useful in the solid block composition ashypohalite-releasing bleaches are halohydantoins which may be usedinclude those which may be represented by the general structure:

wherein:

X₁ and X₂ are independently hydrogen, chlorine or bromine; and,

R₁ and R₂ are independently alkyl groups having from 1 to 6 carbonatoms. Examples of halohydantoins include, for example,N,N′-dichloro-dimethyl-hydantoin, N-bromo-N-chloro-dimethyl-hydantoin,N,N′-dibromo-dimethyl-hydantoin, 1,4-dichloro, 5,5-dialkyl substitutedhydantoin, wherein each alkyl group independently has 1 to 6 carbonatoms, N-monohalogenated hydantoins such as chlorodimethylhydantoin(MCDMH) and N-bromo-dimethylhydantoin (MBDMH); dihalogenated hydantoinssuch as dichlorodimethylhydantoin (DCDMH), dibromodimethylhydantoin(DBDMH), and 1-bromo-3-chloro-5,5-dimethylhydantoin (BCDMH); andhalogenated methylethylhydantoins such as chloromethylethylhydantion(MCMEH), dichloromethylethylhydantoin (DCMEH), bromomethylethylhydantoin(MBMEH), dibromomethylethylhydantoin (DBMEH), andbromochloromethylethylhydantoin (BCMEH), and mixtures thereof. Othersuitable organic hypohalite liberating bleaching agents includehalogenated melamines such as tribromomelamine and trichloromelamine.Suitable inorganic hypohalite-releasing bleaching agents include lithiumand calcium hypochlorites and hypobromites. The various chlorine,bromine or hypohalite liberating agents may, if desired, be provided inthe form of stable, solid complexes or hydrates, such as sodiump-toluene sulfobromamine trihydrate; sodium benzene sulfochloraminedihydrate; calcium hypobromite tetrahydrate; and calcium hypochloritetetrahydrate. Brominated and chlorinated trisodium phosphates formed bythe reaction of the corresponding sodium hypohalite solution withtrisodium orthophosphate (and water, as necessary) likewise compriseuseful inorganic bleaching agents for incorporation into the inventivesolid block composition and the treatment blocks formed therefrom.

When present, preferably the bleach constituent is a hypohaliteliberating compound and more preferably is a hypohalite liberatingcompound in the form of a solid complex or hydrate thereof. Particularlypreferred are chloroisocynanuric acids and alkali metal salts thereof,preferably potassium, and especially sodium salts thereof. Examples ofsuch compounds include trichloroisocyananuric acid, dichloroisocyanuricacid, sodium dichloroisocyanurate, potassium dichloroisocyanurate, andtrichloro-potassium dichloroisocynanurate complex. The most preferredchlorine bleach material is sodium dichloroisocyanurate; the dihydrateof this material being particularly preferred.

When present, the bleach constituent may be present in any effectiveamount and may comprise up to about 90% wt., preferably at least about0.1-60% wt of the compressed solid block composition. More preferably,when present, the bleach constituent comprises about 0.5-50% wt., morepreferably at least 1-40% wt. of the compressed solid block composition.

Other germicidally effective agents useful as sanitizing agents includesodium dichloroisocyanurate (DCCNa) and sodium dibromoisocyanurate.Further examples of non-quaternary ammonium based sanitizing agentsinclude pyrithiones, dimethyldimethylol hydantoin,methylchloroisothiazolinone/methylisothiazolinone sodium sulfite, sodiumbisulfite, imidazolidinyl urea, diazolidinyl urea, benzyl alcohol,2-bromo-2-nitropropane-1,3-diol, formalin (formaldehyde), iodopropenylbutylcarbamate, chloroacetamide, methanamine, methyldibromonitrileglutaronitrile, glutaraldehyde, 5-bromo-5-nitro-1,3-dioxane, phenethylalcohol, o-phenylphenol/sodium o-phenylphenol, sodiumhydroxymethylglycinate, polymethoxy bicyclic oxazolidine, dimethoxane,thimersal dichlorobenzyl alcohol, captan, chlorphenenesin,dichlorophene, chlorbutanol, glyceryl laurate, halogenated diphenylethers, phenolic compounds, mono- and poly-alkyl and aromatichalophenols, resorcinol and its derivatives, bisphenolic compounds,benzoic esters (parabens), halogenated carbanilides,3-trifluoromethyl-4,4′-dichlorocarbanilide, and3,3′,4-trichlorocarbanilide. More preferably, the non-cationicantimicrobial agent is a mono- and poly-alkyl and aromatic halophenolselected from the group p-chlorophenol, methyl p-chlorophenol, ethylp-chlorophenol, n-propyl p-chlorophenol, n-butyl p-chlorophenol, n-amylp-chlorophenol, sec-amyl p-chlorophenol, n-hexyl p-chlorophenol,cyclohexyl p-chlorophenol, n-heptyl p-chlorophenol, n-octylp-chlorophenol, o-chlorophenol, methyl o-chlorophenol, ethylo-chlorophenol, n-propyl o-chlorophenol, n-butyl o-chlorophenol, n-amylo-chlorophenol, tert-amyl o-chlorophenol, n-hexyl o-chlorophenol,n-heptyl o-chlorophenol, o-benzyl p-chlorophenol, o-benzyl-m-methylp-chlorophenol, o-benzyl-m,m-dimethyl p-chlorophenol, o-phenylethylp-chlorophenol, o-phenylethyl-m-methyl p-chlorophenol, 3-methylp-chlorophenol, 3,5-dimethyl p-chlorophenol, 6-ethyl-3-methylp-chlorophenol, 6-n-propyl-3-methyl p-chlorophenol,6-iso-propyl-3-methyl p-chlorophenol, 2-ethyl-3,5-dimethylp-chlorophenol, 6-sec-butyl-3-methyl p-chlorophenol,2-iso-propyl-3,5-dimethyl p-chlorophenol, 6-diethylmethyl-3-methylp-chlorophenol, 6-iso-propyl-2-ethyl-3-methyl p-chlorophenol,2-sec-amyl-3,5-dimethyl p-chlorophenol 2-diethylmethyl-3,5-dimethylp-chlorophenol, 6-sec-octyl-3-methyl p-chlorophenol, p-chloro-m-cresol,p-bromophenol, methyl p-bromophenol, ethyl p-bromophenol, n-propylp-bromophenol, n-butyl p-bromophenol, n-amyl p-bromophenol, sec-amylp-bromophenol, n-hexyl p-bromophenol, cyclohexyl p-bromophenol,o-bromophenol, tert-amyl o-bromophenol, n-hexyl o-bromophenol,n-propyl-m,m-dimethyl o-bromophenol, 2-phenyl phenol, 4-chloro-2-methylphenol, 4-chloro-3-methyl phenol, 4-chloro-3,5-dimethyl phenol,2,4-dichloro-3,5-dimethylphenol, 3,4,5,6-terabromo-2-methylphenol,5-methyl-2-pentylphenol, 4-isopropyl-3-methylphenol,para-chloro-meta-xylenol, dichloro meta xylenol, chlorothymol, and5-chloro-2-hydroxydiphenylmethane.

Quaternary ammonium based sanitizing agents include any cationicsurfactant which is known or may be found to provide a broadantibacterial or sanitizing function; these have been described abovewith reference to detersive surfactants.

As a further chemical constituent, the compressed solid blockcompositions of the invention may also comprise a coloring agent whichimparts either a color to the compressed solid blocks, to the water inwhich it comes into contact, but especially which imparts color to thewater contained within the sanitary appliance. Where the sanitaryappliance is a toilet, desirably the coloring agent imparts a color tothe water contained within the cistern, or within the toilet bowlparticularly following the flush cycle of a toilet, or may impart acolor in both locations. Such coloring agents have great consumerappeal, and indeed any known art coloring agent may be provided in anyeffective amount in order to impart a coloring effect. Colorants,especially dyes, are preferred when formulated as dry powders to enabledirect incorporation into compressed solid blocks of the invention,however, liquid colorants may be employed in conjunction with suitablecarriers. Useful colorants include any materials which may provide adesired coloring effect. Exemplary useful coloring agents include dyes,e.g., Alizarine Light Blue B (C.I. 63010), Carta Blue VP (C.I. 24401),Acid Green 2G (C.I. 42085), Astragon Green D (C.I. 42040) SupranolCyanine 7B (C.I. 42675), Maxilon Blue 3RL (C.I. Basic Blue 80), acidyellow 23, acid violet 17, a direct violet dye (Direct violet 51),Drimarine Blue Z-RL (C.I. Reactive Blue 18), Alizarine Light Blue H-RL(C.I. Acid Blue 182), FD&C Blue No. 1, FD&C Green No. 3 and Acid BlueNo. 9. When a bleach constituent is included in the compressed solidblock composition, the colorant, e.g., dye, should be selected so toensure the compatibility of the colorant with the bleach constituent, orso that its color persists despite the presence in the toilet bowl of aconcentration of hypochlorite which is effective to maintain sanitaryconditions. Frequently however, a compressed solid block compositionwhich includes a bleach constituent do not comprise any colorants.Desirably the colorants, when present, do not exceed 15% wt. of thecompressed solid block composition, although generally lesser amountsare usually effective. When present, colorants are desirably present inan amount from about 0.1 to 15 percent of the total weight of thechemical composition.

The compressed solid block compositions may include a fragrance or otherair treatment constituent. The fragrance may be any composition which isknown to the art to provide a perceptible fragrancing benefit, any maybe based on naturally occurring materials such as one or more essentialoils, or may be based on synthetically produced compounds as well.Examples of essential oils include pine oil, Anetlhole 20/21 natural,Aniseed oil china star, Aniseed oil globe brand, Balsam (Perui), Basiloil (India), Black pepper oil, Black pepper oleoresin 40/20, Bois deRose (Brazil) FOB, Bomneol Flakes (China), Camphor oil, White, Camphorpowder synthetic technical, Canaga oil (Java), Cardamom oil, Cassia oil(China), Cedarwood oil (China) BP, Cinnamon bark oil, Cinnamon leaf oil,Citronella oil, Clove bud oil, Clove leaf, Coriander (Russia), Counmarin69° C. (China), Cyclamen Aldehyde, Diphenyl oxide, Ethyl vanilin,Eucalyptol, Eucalyptus oil, Eucalyptus citriodora, Fennel oil, Geraniumoil, Ginger oil, Ginger oleoresin (India), White grapefruit oil,Guaiacwood oil, Gurjun balsam, Heliotropin, Isobornyl acetate,Isolongifolene, Juniper berry oil, L-methyl acetate, Lavender oil, Lemonoil, Lemongrass oil, Lime oil distilled, Litsea Cubeba oil, Longifolene,Menthol crystals, Methyl cedryl ketone, Methyl chavicol, Methylsalicylate, Musk ambrette, Musk ketone, Musk xylol, Nutmeg oil, Orangeoil, Patchouli oil, Peppermint oil, Phenyl ethyl alcohol, Pimento berryoil, Pimento leaf oil, Rosalin, Sandalwood oil, Sandenol, Sage oil,Clary sage, Sassafras oil, Spearmint oil, Spike lavender, Tagetes, Teatree oil, Vanilin, Vetyver oil (Java), and Wintergreen oil.

Many of these essential function as a fragrance agent which fragranceagent which may be a substance or mixture of various substancesincluding those which are naturally derived (i.e., obtained byextraction of flower, herb, blossom or plant), those which areartificially derived or produced (i.e., mixture of natural oils and/oroil constituents), and those which are synthetically produced substances(odiferous substances). Generally fragrance agents are complex mixturesor blends various organic compounds including, but not limited to,certain alcohols, aldehydes, ethers, alamatic compounds and varyingamounts of essential oils such as from about 0 to about 25% by weight,usually from about 0.05 to about 12% by weight, the essential oilsthemselves being volatile odiferous compounds and also functioning toaid in the dissolution of the other components of the fragrance agent.In the present invention, the precise composition of the fragrance agentdesirably emanates a pleasing fragrance, but the nature of the fragranceagent is not critical to the success of the invention.

As noted above, in conjunction with or in the absence of a fragranceconstituent, the compressed solid block compositions may comprise an airtreatment constituent. Such may be any other material which is useful inproviding treatment of ambient air, such as a sanitizing agents e.g.,one or more glycols or alcohols, or materials which are intended tocounteract, neutralize, or mask odors in the absence of, or inconjunction with, the fragrance composition of the present invention.Alternatively, the air treatment constituent may be one or morematerials which provide and effective insecticide repelling orinsecticidal benefit; such would be particularly useful in climates orenvironments where insects present a nuisance or health hazard.

As further chemical constituents, the compressed solid blockcompositions of the invention may comprise an anti-limescale agent,which can be generally classified as a cleaning agent in that itprovides a cleaning effect to treated lavatory device surfaces. Theanti-limescale agent can virtually any known anti-limescale agentcompositions known to those of ordinary skill in the relevant art. Forexample, compositions containing anionic and/or nonionic surfactantstogether with typical anti-limescale agents, for example, amidosulfonicacid, bisulfate salts, organic acids, organic phosphoric salts, alkalimetal polyphosphates, and the like. Examples of anti-limescale agentcompositions can be found in, for example, U.S. Pat. Nos. 5,759,974;4,460,490; and 4,578,207, the contents of which are herein incorporatedby reference. Further examples of anti-limescale agents include organicacids (for example, citric acid, lactic acid, adipic acid, oxalic acidand the like), organic phosphoric salts, alkali metal polyphosphates,sulfonic, and sulfamic acids and their salts, bisulfate salts, EDTA,phosphonates, and the like.

The compressed solid block compositions may comprise stain inhibitingmaterials. The solid block composition of the invention may, forexample, include an effective amount of a manganese stain inhibitingagent which is advantageously included wherein the sanitary appliance issupplied by a water source having an appreciable or high amount ofmanganese. Such water containing a high manganese content are known tofrequently deposit unsightly stains on surfaces of sanitary appliances,especially when the solid block composition also contains a bleachsource which provides a hypochlorite. To counteract such an effect thesolid block composition of the present invention may comprise amanganese stain inhibiting agent, such as a partially hydrolyzedpolyacrylamide having a molecular weight of about 2000 to about 10,000,a polyacrylate with a molecular weight of about 2000 to about 10,000,and/or copolymers of ethylene and maleic acid anhydride with a molecularweight of from about 20,000 to about 100,000. When present the satininhibiting materials may comprise to about 10% wt. of the weight of thecompressed solid block composition.

The compressed solid block compositions of the invention may include oneor more preservatives. Such preservatives are primarily included toreduce the growth of undesired microorganisms within the treatmentblocks formed from the solid block composition during storage prior touse or while used, although it is expected that the such a preservativemay impart a beneficial antimicrobial effect to the water in thesanitary appliance to which the treatment block is provided. Exemplaryuseful preservatives include compositions which include parabens,including methyl parabens and ethyl parabens, glutaraldehyde,formaldehyde, 2-bromo-2-nitropropoane-1,3-diol,5-chloro-2-methyl-4-isothiazolin-3-one, 2-methyl-4-isothiazoline-3-one,and mixtures thereof. One exemplary composition is a combination5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-4-isothiazolin-3-onewhere the amount of either component may be present in the mixtureanywhere from 0.001 to 99.99 weight percent, based on the total amountof the preservative. For reasons of availability, the most preferredpreservative are those commercially available preservative comprising amixture of 5-chloro-2-methyl-4-isothiazolin-3-one and2-methyl-4-isothiazolin-3-one marketed under the trademark KATHON®CG/ICP as a preservative composition presently commercially availablefrom Rohm and Haas (Philadelphia, Pa.). Further useful preservativecompositions include KATHON® CG/ICP II, a her preservative compositionpresently commercially available from Rohm and Haas (Philadelphia, Pa.),PROXEL® which is presently commercially available from Zeneca Biocides(Wilmington, Del.), SUTTOCIDE® A which is presently commerciallyavailable from Sutton Laboratories (Chatam, N.J.) as well as TEXTAMER®38 AD which is presently commercially available from Calgon Corp.(Pittsburgh, Pa.). When present, the optional preservative constituentshould not exceed about 5% wt. of the solid block composition, althoughgenerally lesser amounts are usually effective.

The inventive compressed solid block compositions may include a binderconstituent. The binder may function in part controlling the rate ofdissolution of the tablet. The binder constituent may be a clay, butpreferably is a water-soluble or water-dispersible gel-forming organicpolymer. The term “gel-forming” as applied to this polymer is intendedto indicate that on dissolution or dispersion in water it first forms agel which, upon dilution with further water, is dissolved or dispersedto form a free-flowing liquid. The organic polymer serves essentially asbinder for the tablets produced in accordance with the inventionalthough, as will be appreciated, certain of the polymers envisaged foruse in accordance with the invention also have surface active propertiesand thereby serve not only as binders but also enhance the cleansingability of the tablets of the invention. Further certain organicpolymers, such as substituted celluloses, also serve as soilantiredeposition agents. A wide variety of water-soluble organicpolymers are suitable for use in the solid block composition of thepresent invention. Such polymers may be wholly synthetic or may besemi-synthetic organic polymers derived from natural materials. Thus,for example, on class of organic polymers for use in accordance with theinvention are chemically modified celluloses such as ethyl cellulose,methyl cellulose, sodium carboxymethyl cellulose, hydroxypropylcellulose, hydroxypropyl methyl cellulose, ethyl hydroxyethyl cellulose,carboxymethyl hydroxyethyl cellulose, and hydroxyethyl cellulose.Another class of organic polymers which may be used include naturallyderived or manufactured (fermented) polymeric materials such asalginates and carageenan. Also, water-soluble starches and gelatin maybe used as the optional binder constituent. The cellulose based bindersare a preferred class of binders for use in the solid block compositionand may possess the property of inverse solubility that is theirsolubility decreases with increasing temperature, thereby rendering thetablets of the invention suitable for use in locations having arelatively high ambient temperature.

The optional binder constituent may also be one or more syntheticpolymers e.g, polyvinyl alcohols; water-soluble partially hydrolyzedpolyvinyl acetates; polyacrylonitriles; polyvinyl pyrrolidones;water-soluble polymers of ethylenically unsaturated carboxylic acids,such as acrylic acid and methacrylic acid, and salts thereof;base-hydrolysed starch-polyacrylonitrile copolymers; polyacrylamides;ethylene oxide polymers and copolymers; as well ascarboxypolymethylenes.

In the case of the organic polymeric binders it may be noted that, ingeneral, the higher the molecular weight of the polymer the greater thein-use life of the treatment block of the invention. When present, thetotal binder content may comprise up to 75% wt. of the solid blockcomposition, but preferably is from 0.5 to 70% by weight, preferablyfrom 1 to 65% by weight, more preferably from 5 to 60% by weight.

The solid block composition may optionally include one or moredissolution control agents. Such dissolution control agent are materialswhich provide a degree of hydrophobicity to the treatment block formedfrom the solid block composition whose presence in the treatment blockcontributes to the slow uniform dissolution of the treatment block whencontacted with water, and simultaneously the controlled release of theactive constituents of the solid block composition. Preferred for use asthe dissolution control agents are mono- or di-alkanol amides derivedfrom C₈-C₁₆ fatty acids, especially C₁₂-C₁₄ fatty acids having a C₂-C₆monoamine or diamine moiety. When included the dissolution control agentmay be included in any effective amount, but desirably the dissolutioncontrol agent is present in an amount not to exceed about 600% wt. ofthe solid block composition, although generally lesser amounts areusually effective. Generally wherein the treatment block is to be usedin an ITB application the dissolution control agent is present to about12% wt., more preferably is present from 0.1-10% wt. and most preferablyis present from about 3-8% wt. of the solid block compositions, as wellas in the treatment blocks formed therefrom. Generally wherein thetreatment block is to be used in an ITC application the dissolutioncontrol agent is present to about 50% wt., more preferably is presentfrom 1-50% wt. and most preferably is present from about 10-40% wt. ofthe solid block compositions, as well as in the treatment blocks formedtherefrom.

The compressed solid block compositions may optionally include one ormore water-softening agents or one or more chelating agents, for exampleinorganic water-softening agents such as sodium hexametaphosphate orother alkali metal polyphosphates or organic water-softening agents suchas ethylenediaminetetraacetic acid and nitrilotriacetic acid and alkalimetal salts thereof. When present, such water-softening agents orchelating agents should not exceed about 20% wt. of the solid blockcomposition, although generally lesser amounts are usually effective.

The compressed solid block composition may optionally include one ormore solid water-soluble acids or acid-release agents such as sulphamicacid, citric acid or sodium hydrogen sulphate. When present, such solidwater-soluble acids or acid-release agents should not exceed about 20%wt. of the solid block composition, although generally lesser amountsare usually effective.

The compressed solid block compositions may include diluent materialsmay be included to provide additional bulk of the product solid blockcomposition and may enhance leaching out of the surfactant constituentwhen the solid block composition is placed in water. Exemplary diluentmaterials include any soluble inorganic alkali, alkaline earth metalsalt or hydrate thereof, for example, chlorides such as sodium chloride,magnesium chloride and the like, carbonates and bicarbonates such assodium carbonate, sodium bicarbonate and the like, sulfates such asmagnesium sulfate, copper sulfate, sodium sulfate, zinc sulfate and thelike, borax, borates such as sodium borate and the like, as well asothers known to the art but not particularly recited herein. Exemplaryorganic diluents include, inter alia, urea, as well as water solublehigh molecular weight polyethylene glycol and polypropylene glycol. Whenpresent, such diluent materials should not exceed about 80% wt. of thecompressed solid block composition, although generally lesser amountsare usually effective.

The compressed solid block composition and treatment blocks formedtherefrom may include one or more fillers. Such fillers are typicallyparticulate solid water-insoluble materials which may be based oninorganic materials such as talc or silica, particulate organicpolymeric materials such as finely comminuted water insoluble syntheticpolymers. When present, such fillers should not exceed about 30% wt. ofthe compressed solid block composition, although generally lesseramounts are usually effective.

Preferably the compressed solid block of the invention includes silica.Silica has been observed to aid in the controlling the rate ofdissolution of the compressed solid blocks of the invention.

The compressed solid block composition and treatment blocks formedtherefrom may include one or more further processing aids. For example,the solid block composition may also include other binding and/orplasticizing ingredients serving to assist in the manufacture thereoffor example, polypropylene glycol having a molecular weight from about300 to about 10,000 in an amount up to about 20% by weight, preferablyabout 4% to about 15% by weight of the mixture may be used. Thepolypropylene glycol reduces the melt viscosity, acts as a demoldingagent and also acts to plasticize the block when the composition isprepared by a casting process. Other suitable plasticizers such as pineoil fractions, d-limonene, dipentene and the ethylene oxide-propyleneoxide block copolymers may be utilized. Other useful processing aidsinclude tabletting lubricants such as metallic stearates, stearic acid,paraffin oils or waxes or sodium borate which facilitate in theformation of the treatment blocks in a tabletting press or die.

One advantageously utilized processing aid is a diester constituentwhich may be represented by the following structure:

wherein:R¹ and R² can independently be C₁-C₆ alkyl which may optionallysubstituted,Y is (CH₂)_(x), wherein x is 0-10, but is preferably 1-8, and while Ymay be a linear alkyl or phenyl moiety, desirably Y includes one or moreoxygen atoms and/or is a branched moiety.

Exemplary diester constituents include the following diester compoundsaccording to the foregoing structure: dimethyl oxalate, diethyl oxalate,diethyl oxalate, dipropyl oxalate, dibutyl oxalate, diisobutyl oxalate,dimethyl succinate, diethyl succinate, diethylhexyl succinate, dimethylglutarate, diisostearyl glutarate, dimethyl adipate, diethyl adipate,diisopropyl adipate, dipropyl adipate, dibutyl adipate, diisobutyladipate, dihexyladipate, di-C₁₂₋₁₅-alkyl adipate, dicapryl adipate,dicetyl adipate, diisodecyl adipate, diisocetyl adipate, diisononyladipate, diheptylundecyl adipate, ditridecyl adipate, diisostearyladipate, diethyl sebacate, diisopropyl sebacate, dibutyl sebacate,diethylhexylsebacate, diisocetyl dodecanedioate, dimethyl brassylate,dimethyl phthalate, diethyl phthalate, dibutyl phthalate.

Preferred diester constituents include those wherein Y is —(CH₂)_(x)—wherein x has a value of from 0-6, preferably a value of 0-5, morepreferably a value of from 1-4, while R¹ and R² are C₁-C₆ alkyl groupswhich may be straight chained alkyl but preferably are branched, e.g,iso- and tert-moieties. Particularly preferred diester compounds arethose in which the compounds terminate in ester groups.

A further advantageously utilized processing aid is a hydrocarbonsolvent constituent. The hydrocarbon solvents are immiscible in water,may be linear or branched, saturated or unsaturated hydrocarbons havingfrom about 6 to about 24 carbon atoms, preferably comprising from about12 to about 16 carbon atoms. Saturated hydrocarbons are preferred, asare branched hydrocarbons. Such hydrocarbon solvents are typicallyavailable as technical grade mixtures of two or more specific solventcompounds, and are often petroleum distillates. Nonlimiting examples ofsome suitable linear hydrocarbons include decane, dodecane, decene,tridecene, and combinations thereof. Mineral oil is one particularlypreferred form of a useful hydrocarbon solvent. Further preferredhydrocarbon solvents include paraffinic hydrocarbons including bothlinear and branched paraffinic hydrocarbons. The former are commerciallyavailable as NORPAR solvents (ex. ExxonMobil Corp.) while the latter areavailable as ISOPAR solvents (ex. ExxonMobil Corp.) Mixtures of branchedhydrocarbons especially as isoparaffins form a further particularlypreferred form of a useful hydrocarbon solvent of the invention.Particularly useful technical grade mixtures of isoparaffins includemixtures of isoparaffinic organic solvents having a relatively narrowboiling range. Examples of these commercially available isoparaffinicorganic solvents include ISOPAR C described to be primarily a mixture ofC₇-C₈ isoparaffins, ISOPAR E described to be primarily a mixture ofC₈-C₉ isoparaffins, ISOPAR G described to be primarily a mixture ofC₁₀-C₁₁ isoparaffins, ISOPAR H described to be primarily a mixture ofC₁₁-C₁₂ isoparaffins, ISOPAR J, ISOPAR K described to be primarily amixture of C₁₁-C₁₂ isoparaffins, ISOPAR L described to be primarily amixture of C₁₁-C₁₃ isoparaffins, ISOPAR M described to be primarily amixture of C₁₃-C₁₄ isoparaffins, ISOPAR P and ISOPAR V described to beprimarily a mixture of C₁₂-C₂₀ isoparaffins.

When present such further processing aids are typically included inamounts of up to about 30% by weight, preferably to 20% wt. of the solidblock composition, although generally lesser amounts are usuallyeffective.

Optionally but in some cases, preferably one or more of the foregoingconstituents may be provided as an encapsulated, particularly amicroencapsulated material. That is to say, quantities of one or moreconstituents are provided covered or encapsulated in an encapsulatingmaterial. Methods suitable for such an encapsulation include thecustomary methods and also the encapsulation of the granules by a meltconsisting e.g. of a water-soluble wax, coacervation, complexcoacervation and surface polymerization. Non-limiting examples of usefulencapsulating materials include e.g. water-soluble, water-dispersible orwater-emulsifiable polymers and waxes. Advantageously, reactive chemicalconstituents, particularly the fragrance composition when present, maybe provided in an encapsulated form so to ensure that they do notprematurely degrade during processing of the constituents used to formthe compressed solid block composition and that they are retained withminimal degradation in the compressed solid block composition prior totheir use. The use of water soluble encapsulating material is preferredas such will release the one or more chemical constituents when thecompressed solid block composition is contacted with water suppliedeither in the cistern or in the toilet bowl.

Ideally the compressed solid blocks exhibit a density greater than thatof water which ensures that they will sink when suspended in a body ofwater, e.g., the water present within a cistern. Preferably thetreatment blocks formed from the solid block composition exhibit adensity in excess of about 1 g/cc of water, preferably a density inexcess of about 1.5 g/cc of water and most preferably a density of atleast about 2 g/cc of water.

While the mass of the compressed solid blocks may vary, and amount of upto an including 500 grams may be practiced, generally the mass of thecompressed solid block compositions do not exceed about 150 grams.Advantageously the mass of the compressed solid blocks is between about20 and 100 grams. It is appreciated that compressed solid blocks havinggreat mass should provide a longer useful service life of the cagelesslavatory devices, with the converse being equally true.

The compressed solid blocks according to the present invention may alsobe provided with a coating of a water-soluble film, such as polyvinylacetate following the formation of the treatment blocks from the recitedsolid block composition. Such may be desired for improved handling,however such is often unnecessary as preferred embodiments of thecompressed blocks exhibit a lower likelihood of sticking to one anotherfollowing manufacture than many prior art treatment block compositions.

It will be appreciated by those of ordinary skill in the art thatseveral of the components which are directed to provide a chemicalcomposition can be blended into one chemical composition with theadditional appreciation that potential blending of incompatiblecomponents will be avoided. For example, those of ordinary skill in theart will appreciate that certain anionic surfactants may have to beavoided as some may be incompatible with certain sanitizing agentsand/or certain anti-lime scale agents mentioned herein. Those ofordinary skill in the art will appreciate that the compatibility of theanionic surfactant and the various sanitizing and anti-limescale agentscan be easily determined and thus incompatibility can be avoided in thesituations.

The compressed solid blocks may be formed of a single chemicalcomposition, or may formed of two (or more) different chemicalcompositions which may be provided as separate regions of a solid block,such as a first layer of a solid block consisting of a first chemicalcomposition, alongside a second layer of a the solid block consisting ofa second chemical composition which is different than the first chemicalcomposition. The block may also be formed of two or more separate blockswhich are simply layered or otherwise assembled, without or without theuse of an adhesive. Further layers of still further different chemicalcompositions may also be present. Such solid blocks formed having two ormore discrete layers or regions of, respectively, two or more differentchemical compositions may be referred to as composite blocks.

Any form of the compressed solid blocks may also be provided with acoating film or coating layer, such as a water soluble film which isused to overwrap the chemical composition provided in the device whichfilm provides a vapor barrier when dry, but which dissolves whencontacted with water. Alternately the compressed solid blocks may beoversprayed or dipped into a bath of a water soluble film formingconstituent, and thereafter removed and thus allowing the water solublefilm forming constituent to dry and form a coating layer on thecompressed solid block.

Exemplary materials which may be used to provide such a coating on someor all of the surfaces of the compressed solid block compositionsinclude one or more of the following: Rhodasurf TB-970 described by itssupplier to be a tridecyl alcohol having a degree of ethoxylation ofapproximately 100 having an HLB of 19, and exhibiting a melting point inthe range of 52-55° C.; Antarox F-108 which is described to be an EO-POblock copolymer having a degree of ethoxylation of approximately 80% andhaving a melting point in the range of 54-60° C.; further materialsincluding those identified as Pluriol Z8000, and Pluriol E8000 which arebelieved to be optionally substituted, high molecular weightpolyethylene glycols (“PEG”) having a sufficiently high molecular weightsuch that they have a melting point of at least 25° C., preferably amelting point of at least about 30° C. may also be used. Other watersoluble materials, desirably those which have a melting point in therange of about 30-70° C., and which may be used to provide a watersoluble or water dispersible coating on the compressed solid blocks arealso contemplated to be useful, especially synthetic or naturallyoccurring waxy materials, and high molecular weight polyalkyleneglycols, especially polyethylene glycols. Certain of these coatingmaterials may be surfactants. Generally such materials may be providedas a dispersion in water, an organic solvent or in an aqueous/organicsolvent, but preferably are used as supplied from their respectivesupplier and are heated to at least their melting points in order toform a liquid bath. Conveniently, the compressed solid blocks affixed tothe plate of a hanger are then conveniently dipped into the said bath,thereby providing a coating layer to the compressed solid blocks.Alternately, the coating materials may be sprayed, brushed on or paddedonto at least part of the surfaces of the previously formed compressedsolid blocks.

The application of a water soluble film or coating is preferred incertain embodiments of the invention as the surface film may facilitatethe handling of the blocks during packaging and storage prior to use ofthe cageless lavatory devices. Further, the application of a watersoluble film or coating is preferred as certain water soluble filmformer compositions may impart a desirable surface gloss to thecompressed lavatory blocks.

Preferably the compressed solid block compositions useful in thecageless lavatory devices include those which comprise at least onesurfactant, preferably at least one anionic or nonionic surfactant.

Exemplary compositions which can be used to form the compressed solidblocks of the present invention are shown in the following table below;the amounts indicates are in % wt. of the “as supplied” constituent usedto form an example block compositions, labeled A through F. Component AB C E F Dodecyl Benzene Sulfonate Na¹ 25 10 40 35 35 Alfa OlefineSulfonate Na² 25 10  5 32 32 Lauryl monoethanolamide³ 10  8  5 2  5Sodium Lauryl Ether Sulfate⁴ 10 — — 4.5  5 Pluronic 68⁵ 10 — — 3 — NaSulfate 20 — — 21.5 21 Pluronic 87 or 88⁶ — 70 50 — — Alcohol ethoxylateC₉-C₁₁ 6EO⁷ —  2 — — — Silica — — — 2  2¹Dodecyl Benzene Sulfonate Sodium (80-90% active) -- anionic²Alpha Olefin Sulfonate Sodium -- anionic³Lauryl Monoethanolamide -- non-ionic⁴Sodium Lauryl Ether Sulfate (70% active) -- anionic⁵Polyoxyethylene (160) polyoxypropylene (30) glycol - non-ionic⁶Pluronic 87 E₆₁ P_(41.5) E₆₁ -- Molecular Weight 7700 -- HLB 24 --non-ionic Pluronic 88 E₉₈ P_(41.5) E₉₈ -- Molecular Weight 10800 -- HLB28-- non-ionic⁷Alcohol ethoxylate C₉-C₁₁ 6EO -- non-ionic

Further exemplary bleach containing compositions which can be used toform the compressed solid blocks of the present invention includecompositions indicated on the next table having the general ranges asfollows: % w/% w alpha olefin sulfonate  0-35 Sodium lauryl ethersulfate 3.0-6.0 Bleaching agent (e.g., DCCNa or Hydantoin) 0.5-25 Lauryl monoethanolamide 2.0-5.0 Dodecyl benzene sulfonate Na 50-70 Nasulfate anhydrous 15-25 Silica 1.0-2.0

Further exemplary preferred embodiments of blocks which are useful ascompressed solid blocks of the present invention include those whichcomprise:

10-35% wt., preferably 15-30% wt. of an alpha olefin sulfonate anionicsurfactant;

10-35% wt., preferably 15-30% wt. of a linear monoethanolamide;

5-50% wt., preferably 15-35% wt. of a linear dodecylbenzene sulfonateanionic surfactant;

5-50% wt, preferably 20-35% wt. of sodium sulfate

0.1-15% wt., preferably 0.5-5% wt. of silica

0.1-25% wt., preferably 1-10% wt. sodium lauryl ether sulfate

optionally to 40% wt. further additive constituents, including but notlimited to further surfactants, fillers, binders, fragrances, processingaids such as lubricants and tabletting aids, bleaches, sanitizingcompositions and the like.

Yet further exemplary compositions which include a bleach constituentwhich find use as compressed solid blocks of the present inventioninclude those recited on the following tables, and labeled as C throughN: G H I J K L dodecylbenzene 27.0 22.0 32.0 35.00 37.8 32.0 sulfonate,sodium salt (80%) sodium C14/C16 15.0 20.0 15.0 22.0 23.62 20.0 olefinsulfonates (80%) silica 2.0 2.0 2.0 2.0 1.89 2.0 lauramide monoethanol30.0 30.0 25.0 15.00 12.28 20.0 amide (98%) sodium sulfate 20.5 20.520.5 20.50 18.90 20.5 dichlorocyanurate 2.5 2.5 2.5 2.4 2.41 2.5dihydrate, sodium salt (56% bleach) paraffinic 3.0 3.0 3.0 3.1 3.09 3.0hydrocarbons M N O dodecylbenzene sulfonate, 35.0 37.0 32.0 sodium salt(80%) olefin sulfonates (80%) sodium C14/C16 22.0 25.0 20.0 silica 2.02.0 2.0 lauramide monoethanol 15.0 10.0 20.0 amide (98%) sodium sulfate20.5 20.5 18.5 dichlorocyanurate 2.5 2.5 2.5 dihydrate, sodium salt (56%bleach) paraffinic 3 3 5 hydrocarbons

The identity of the constituents used to form the foregoing compressedsolid blocks G-O are identified more specifically on the followingtable. dodecylbenzene anionic surfactant, dodecylbenzene sulfonate,sulfonate, sodium 80% wt. actives salt (80%) sodium C14/C16 anionicsurfactant, sodium C14/C16 olefin olefin sulfonates (80%) sulfonates,80% wt. actives silica filler anhydrous silica, 100% wt. actives.lauramide monoethanol solubility control agent, lauramide monoethanolamide (98%) amide, 98% wt. actives sodium sulfate diluent, sodiumsulfate, 100% wt. actives dichlorocyanurate bleach constituent,dichlorocyanurate dihydrate, dihydrate, sodium sodium salt, 56% wt.bleach actives salt (56%) Isopar M hydrocarbon solvent, isoparaffinicorganic solvents, 100% wt. actives mineral oil Hydrocarbon solvent,mineral oil, 100% wt. actives paraffinic hydrocarbons Hydrocarbonsolvent, white paraffin oil, 100% wt. actives

Still further exemplary compositions which include diisopropyl adipateswhich find use as compressed solid blocks of the present inventioninclude those recited on the following tables, and labeled as P throughW: P Q R S dodecylbenzene sulfonate, sodium salt (80%) 55.85 58.85 62.5162.51 silica 2.41 2.41 2.56 2.56 lauramide monoethanolamide (98%) 6.016.01 6.38 6.38 sodium sulfate 12 12 12.75 12.75 dichlorocyanuratedihydrate, sodium salt 14.63 14.63 9.32 9.32 (56%) diisopropyl adipate6.1 6.1 6.48 6.48 T U V W dodecylbenzene sulfonate, sodium salt (80%)58.61 67.27 69.25 70.83 silica 2.40 1.91 1.96 2.01 lauramidemonoethanolamide (98%) 5.98 4.74 4.88 4.99 sodium sulfate 11.95 17.3717.88 18.29 dichlorocyanurate dihydrate, sodium salt 14.6 4.98 2.41 0.55(56%) diisopropyl adipate 6.46 3.73 3.61 3.33

The identity of the constituents used to form the foregoing compressedsolid blocks labeled P through W are identified more specifically on thefollowing table: dodecylbenzene anionic surfactant, dodecylbenzenesulfonate, sulfonate, sodium 80% wt. actives salt (80%) silica anhydroussilica, 100% wt. actives. lauramide solubility control agent, lauramidemonoethanolamide monoethanolamide, 98% wt. actives (98%) sodium sulfatediluent, sodium sulfate, 100% wt. actives dichlorocyanurate bleachconstituent, dichlorocyanurate dihydrate, dihydrate, sodium sodium salt,56% wt. bleach actives salt (56%) diisopropyl adipate diesterconstituent, diisopropyl adipate, 100% wt. actives

Yet further exemplary compositions which include paraffinic hydrocarbonsolvents or mineral oil which find use as compressed solid blocks of thepresent invention include those recited on the following tables, andlabeled as AA through AK: AA AB AC AD AE dodecylbenzene 65.8 65.8 6564.17 69.25 sulfonate, sodium salt (80%) silica 2.69 2.69 2.66 2.63 1.96lauramide 6.72 6.72 6.64 6.55 4.88 monoethanolamine (98%) sodium sulfate13.42 13.42 13.26 13.09 17.88 dichlorocyanurate 8.89 8.89 8.78 9.57 2.41dihydrate, sodium salt (56% bleach) Isopar M 2.47 2.47 — — — mineral oil— — 3.66 3.99 3.61 AF AG AH AI AJ AK dodecylbenzene 70.83 69.25 69.2569.25 70.83 68.31 sulfonate, sodium salt (80%) silica 2.01 1.96 1.961.96 2.01 2.90 lauramide 4.99 4.88 4.88 4.88 4.99 4.88 monoethanolamine(98%) sodium sulfate 18.29 17.88 17.88 17.88 18.29 17.88dichlorocyanurate 0.55 2.41 2.41 2.41 0.55 2.41 dihydrate, sodium salt(56% bleach) Isopar M 3.33 3.61 3.61 — — 3.61 mineral oil — — — 3.613.33 —

The identity of the constituents used to form the foregoing blocks AAthrough AK are identified more specifically on the following table:dodecylbenzene anionic surfactant, dodecylbenzene sulfonate, sulfonate,sodium 80% wt. actives salt (80%) silica filler anhydrous silica, 100%wt. actives. lauramide solubility control agent, lauramidemonoethanolamide monoethanolamide, 98% wt. actives (98%) sodium sulfatediluent, sodium sulfate, 100% wt. actives dichlorocyanurate bleachconstituent, dichlorocyanurate dihydrate, dihydrate, sodium sodium salt,56% wt. bleach actives salt (56%) Isopar M hydrocarbon solvent,isoparaffinic organic solvents, 100% wt. actives mineral oil Hydrocarbonsolvent, mineral oil, 100% wt. actives

Yet further and particularly preferred embodiments of compressed solidblocks and their compositions include those which are recited on Table1.

The manufacture of the cageless lavatory device first contemplatesmixing the constituents of the block composition into a generallyhomogenous mass such as by noodling, as well as by plodding, butpreferably by extruding, and thereafter forming a “preform” from ameasured quantity of the homogenous mass. Usually all of the solidingredients are mixed in any suitable blending equipment followed by theaddition of liquid ingredients under blending conditions. In anextrusion process a mixture of the chemical constituents used toultimately form the compressed solid block composition is made, followedby extrusion of this mixture into a rod or bar form which is then cutinto appropriately sized pieces or blocks which are to be used in thesubsequent, separate compression process. These pieces or blocks ofextrudate are the preforms. When the compressed solid block is formedfrom a single perform it is required to provide a cavity, channel orrecess within the preform of suitable dimensions to accept at least theplate of a hanger. Conveniently a channel may be provided by cutting aslot in the preform of sufficient depth and width such that the platemay be fully inserted into the interior of the preform prior to thesubsequent compression process. The channel may be cut, or carved suchas by the use of a saw, or other cutting device which will either splitor shape the preform adequately to provide such a suitable sized channelor recess. Alternately a channel may be providing by extruding through adie which includes a blade or other cutter means which extends into theopen cross-section of the die such that as the extrudate exits the die,it is provided with such a channel which partially splits the extrudateinto the legs of a “V”, which remain attached however at the base ofeach leg. Such a channel may extend across the length of the preform andthrough the ends thereof. Alternately, subsequent to extrusion a toolsuch as a plunging blade may be used to partially split a portion of apreform in order to provide a cavity or slot which is of sufficientwidth and depth to accommodate at least the plate of the hanger. Such acavity formed by such blade typically does not extend across the lengthof the preform nor through the ends thereof.

In a next process step, the plate of a hanger is inserted within theinterior of the channel or cavity such that the plate is preferablywholly encased within the interior of the preform. Preferably also thehanger extends outwardly from the preform at an angle which isapproximately perpendicular to, more specifically 90°+/−10°, preferably90°+/−5° with respect to tangent of the surface from which point thehanger extends outwardly therefrom. Such ensures that consistent loadingand proper weight distribution of the hook, and proper placement of thecageless device in the sanitary appliance, especially a toilet ismaintained.

Advantageously the cavity, channel or recess is essentially planar inconfiguration and is situated within the compressed solid block suchthat the plate is not placed within the symmetrical center or themid-plane of the said block but rather is positioned to be parallel to aface or surface of the block such that the plate is positioned within aplane which is at a distance between 10%-80%, preferably 30%-70% of thedistance between the face of surface of the said block, and thesymmetrical center or the mid-plane of the said block. Furtherpreferably, the hanger and the compressed solid block is so positionedwith respect to one another that the face of the said block nearest tothe embedded plate is on the side opposite of the hook end of thehanger.

Alternately the extrudate may be of an alternate configuration, e.g., arectangular, square or oblate cross-sectional configuration, which isformed into preforms. A cavity, channel or recess within the preform isnot required as in an alternative process to the above, two or morediscrete preforms are used together with then plate of the hangerpositioned intermediate two adjacent preforms which are subsequentlycompressed.

The preform comprising the hanger is then compressed in a die whichimparts the final shape to the compressed solid block. This compressionstep may be practiced as a single compression operation or as a seriesof compression steps, i.e., with two or more stamping or compressionoperations. Advantageously the preform(s) are positioned in a die suchthat the plane of the plate of the hanger is parallel to the opposingmajor faces of the compression dies which are brought together.Optionally a mold release agent, such as a waxy material or an oil, suchas a paraffin oil or mineral oil may be applied to one or more surfacesof the die. Such may improve the ease of release of the compressed solidblock, and/or aid in the formation of a smooth external surface to thecompressed solid block. Following compression the compressed solid blockare affixed onto the hanger, and may be removed from or ejected from thedie. The cageless delivery device thus formed is ready for use.

As noted previously the preform used to form the compressed solid blocksmay be formed from a plurality of preforms which are convenientlylayered in register, with the hanger inserted between two preforms inthe orientation as described above. For example, two or more physicallyseparate preforms may be layered in register to form a laminatedcompressed solid block. Such may be desired when it is intended that thecompressed solid block be formed from two or more masses havingdifferent chemical compositions. For example, it is contemplated thatthe compressed solid mass may be formed from a first preform having afirst chemical composition, compressed to a second preform having asecond chemical composition which is different than the first chemicalcomposition. By way of non-limiting example, the first preform may be ofa first color, while the second preform may be of different, secondcolor so that when compressed the preforms are compressed to form asingle compressed solid block having two different colored layers. Ofcourse, three or more preforms may be compressed to form a singlecompressed block. Again the chemical compositions of the first, secondand third preforms may be of the same, similar or of differentcompositions.

During the compression step, several simultaneous technical effectsoccur. The block compositions are densified due to the compression, andconcurrently the embedded hanger is sealed and mechanically anchoredwithin the interior of the block. Preferably the density of thecompressed solid block as at least 1.5% greater than the density of thedensity of the extrudate. Preferably the density of the compressed solidblock is at least 2%, more preferably at least 3% greater than thedensity of the preform or extrudate from which it is formed.Additionally during the compression step, the channel, slot or recesswhich had been formed to accept the hanger is sealed to form a smoothsurface. Still further the exterior surface of the block compositiontakes on the volume configuration and the surface shape of the die. Suchis particularly advantageous when the interior surface of the die issmooth walled which will, in preferred embodiments, impart a smoothexterior surface to the compressed solid block.

In certain particularly preferred embodiments the compressed solidblocks of the present invention weigh from 15 to 150 grams, preferablyfrom about 20 to about 75 grams. The blocks are typically oblate inshape, having a length of from about 1 to about 4 inches and having athickness of from about 0.5-1.5 inches.

The service life of the compressed solid blocks should be from about 10to about 90 days, based on 12 flushes per day. Preferably the servicelife of the compressed solid blocks is at least about 14 days wheninstalled on the rim of a toilet bowl such that the said block ispositioned adjacent to the sloping interior sidewall of the toilet bowland is subjected to between 6-12 flushes per day. Preferably thetemperature of the water which is flushed is in the range of 16-24° C.The length of life of the compressed solid blocks will of course dependon a variety of factors including product formulation, watertemperature, tank size, the number of flushes over the period of use andthe volume of the water which contacts the compressed solid blocks.

Various configurations of the cageless lavatory device, includingcertain particularly preferred embodiments, are depicted on thefollowing figures. In the accompanying figures, like elements areindicated using the same numerals throughout the figures.

FIG. 1 depicts a hanger 10 comprising a hook end 20 comprising an endmember 12 flexibly attached to a top member 14 as well as part of thestalk 16. Depending from the end of the stalk 16 distally from the hookend 20 is a plate 30. As can be seen from the perspective view providedby FIG. 1, the plate itself is generally rectangular in configuration,and it is coplanar with the ribbon-type or strip-type configuration andconstruction of both the stalk 16 and hook end 20. The plate 30 has awidth dimension “W1” as well as a height dimension “H1” and as depicted,desirably the width is greater than the height. As is visible from thefigure, the hanger 10 is generally symmetrical about a center line “CL”which is drawn with respect to the midline of the stalk 16. The centerline does not exist as an actual element of the device but isillustrated for the sake of convenient reference. While not illustratedwith sufficient particularity in the figure, it is of course understoodthat the plate, stalk 16 and the hook end 20 all have a thickness whichmay be consistent throughout, or which can vary.

FIG. 2 depicts a side view of a further embodiment of the hanger 10 ofFIG. 1. As is more clearly seen in this figure, the hook end 20 isformed from first and second elements 12, 14 and part of the stalk 16.Depending from the stalk 16 is the plate 30. In this embodiment theplate 30 has a thickness “T1” which is greater than the thickness “T2”of the stalk 16 and the hook end 20. Of course, it will be understoodthat each of the hook end, stalk, and plate can have differentthicknesses or can all share the same thickness as illustrated in FIG.1.

FIG. 3 depicts a further embodiment of a hanger 10 according to theinvention, in which the hook end 20 is a flexible element. As can beseen from the figure, the hook end is comprised of a first element 12flexibly connected to a top element 14 which in turn is flexiblyconnected to the stalk 16. At the end opposite the hook end, depends theplate 30. With regard to the hook end, as can be seen, at the terminalend of the first element 12 is seen a broadened region which is referredto as a “pad” 15. The pad region is of the same thickness as the firstelement 12, but is slightly broader. The width of the pad end 15 isgreater than the width of the first element 12. This increased width issometimes useful to stabilize the hook end of the cageless lavatorydevice when suspended upon part of a sanitary appliance. As is furthervisible from FIG. 3, the plate 30 is substantially planar inconfiguration has a width W1 as well as height H1 and is symmetricaround the center line CL of the stalk 16. The plate has a generallylinear bottom edge 39 at opposite ends thereof to generally straight endwalls 36, 38 which end walls proceed and extend to the stalk 16 viasloping top walls 32, 34.

FIG. 4 depicts the hanger 10 of FIG. 3 in both a “folded” as well as inan “unfolded” configuration.

As seen from the solid line elements depicted on FIG. 4, the hanger 10on the folded configuration illustrates, that when the hook end and thestalk are untensioned, the hook end 20 is retained in a closedconfiguration. In the unfolded configuration, as depicted by theelements depicted in a broken line format, the first element 12′ and thepad 15′ are extended away from the stalk 16 and are more distantlypositioned with respect to the stalk than in the prior, foldedconfiguration. Typically, this also causes a degree of translation ofthe top element 14′ which may extend down to, include a portion of thestalk 16′ as well. When made of a flexible material, in the unfoldedconfiguration as depicted in FIG. 4, the elastic bias of the material ofconstruction, such as a polymer, tends to cause the hook end to seek toreturn to the folded configuration. However, when placed about the rimof a portion of a sanitary device, i.e. a toilet bowl, this actioncauses the hook end to impart a degree of gripping to that portion ofthe rim upon which it is mounted. This is turn helps retain the relativeposition of the hook end, as well as that of the cageless lavatorydevice until repositioned, or removed by a consumer.

FIG. 5 depicts a still further embodiment of a hanger 10. In thisembodiment, the hanger includes a coiled hook end 20 comprised of thefirst element 12, the second element 13 and a top element 14 which is ina compressed, coiled arrangement thus making it particularly convenientto include in a consumer package. The top end of the top element 14extends to a stalk 16 having at its opposite end a depending plate 30.In this configuration, the plate 30 is oblate in shape and is generallysymmetrical about a center line (CL). The plate has a width dimension(W1) as well as a height dimension (H1). Further, the plate illustratesthat it can be produced with perforations passing there through. Here,two similarly shaped, generally triangular passages 33, 33′ areprovided. As has been discussed previously in the specification, whileit is contemplated that the plate of the hanger may include one or moreperforations passing there through, for reasons observed although notyet fully understood by the applicants, it is believed that the use ofplates having such perforations passing there through are to bepreferably avoided as such may undesirably reduce the service life ofthe cageless lavatory device.

FIG. 6 depicts a still further embodiment of a hanger 10 according tothe invention. As is shown, the hanger includes a hook end which iscomprised of the first element 12, flexibly connected to a secondelement 13, which is in turn flexibly connected to a top element 14,which in turn is flexibly connected to a part of the stalk 16. Theopposite end of the stalk terminates in a generally oblate shaped plate30 having a width dimension (W1), a height dimension (H1) wherein theplate is generally symmetrically about the center line (CL) as depictedin the dotted line drawn on FIG. 6. Whereas the hanger is depicted in afolded or otherwise coiled configuration, it is to be understood thatthe hook end can be extended by a user of the hanger and the cagelesslavatory device to reconfigure said hook end 20 to form a hook end whichcan be used to suspend the hanger and the cageless lavatory device upona part of a sanitary device particularly a toilet bowl rim. Theembodiment according to FIG. 6 also illustrates that, according topreferred embodiments, the plate 30 is substantially planar and as isshown in FIG. 6, it is of generally uniform thickness. The embodimentdepicted in FIG. 6 is preferred in that the hook end is particularlywell coiled when in its folded configuration, but when uncoiled or inits unfolded configuration, provides a significant degree of tensionwhich is useful in retaining the respective position of the cagelesslavatory device when installed upon a sanitary appliance, particularlywhen the hook is affixed on a part of a toilet bowl rim. Furthermore,FIG. 6 depicts that that embodiment also includes a slanting neck 17formed as part of the stalk 16 and immediately adjacent to the region ofthe plate 30 which is connected to the stalk 16. As depicted, the neckpositions the plate at a position which is beneath the major portion ofthe stalk 16 but is parallel thereto. This positioning beneath the majorpart of the stalk 16 is beneficial and ultimately, it acts to alsothereby position the compressed solid block enrobing the plate 30 suchthat when mounted upon a toilet bowl, the compressed solid block is incontact with, or is in very proximity to the interior sloping side wallof a toilet bowl. Such positioning is advantageous in that it ensuresthat the compressed solid block remains in the flow path of the flushwater throughout the useful service life of the cageless lavatorydevice.

FIGS. 7A through 7D depict various alternate configurations which mayalso be used for the plate 30 for the hanger as described herein. FIG.7A depicts a diamond-shaped plate 30 depending at one vertex from thestalk 16. FIG. 7B depicts a substantially circular plate 30 dependingfrom one part of its circumference from the stalk 16. FIG. 7C depicts anequilateral-triangular shaped plate 30 depending at one vertex from thestalk 16. FIG. 7D depicts a further plate 30 which is generallyrectangular but having two opposite semi-circular ends depending fromthe stalk 16. In each of the foregoing, it is seen that theconfiguration of the plates is generally symmetrical about the centerline, CL.

FIG. 8 depicts an embodiment of a portion of the hanger wherein theplate 30 includes a series of perforations 33 passing there through. Asis depicted, the perforations are not symmetrical with respect to eitherthe center line CL or the configuration of the semi-circular shapedplate 30. As noted above, plates 30 having perforations passing therethrough are less preferred embodiments of the hangers and useful withthe cageless lavatory devices taught herein.

FIGS. 9A and 9B depict in two views an embodiment of a plate 30depending from a stalk 16 wherein the plate comprises at least one, herea plurality of projections 35 extending outwardly from the generallyplanar and opposite faces 37, 37′ of the plate. As is seen in particularin FIG. 9B, the projections 35 are in the form of generally cylindricalstuds having a base coincident with the respective face 37, 37′ of theplate 30. The studs terminate at flat ends. The studs have a heightwhich is approximately equal to, or slightly greater than thickness ofthe plate 30. Again, while these figures depict the utility of outwardlyextending elements extending outward from the plate, again, as notedabove embodiments of the hanger having such outwardly extending elementsfrom the plate are less preferred.

FIGS. 10A and 10B depict two views of an embodiment of a two-partcageless lavatory device 10 of the invention. FIG. 10A depicts aperspective view of a hook end 20 comprising a first element 12, a topelement 14 and a front element 14′ having extending from a part thereofa hanger peg 40. The hook end 20 is configured to be suspended upon therim of a toilet bowl “WC” and may be used a single time but desirably isused several times by a consumer. The second part of the cagelesslavatory device of the invention 10 includes a stalk 16 having at aproximal end an eyelet or loop 44 which is sufficiently sized so thatthe stalk 16 may be removably affixed to and suspended from the hangerpeg 40. The stalk 16 extends downwardly from the proximal end to thedistal end and includes a slanting neck 17, which terminates in plate 30which is encased in a compressed solid block 50. This second part may beinstalled by a user, and when the compressed solid block 50 is consumed,this second part may be removed by the consumer and replaced with afurther second part with a new compressed solid block 50 and utilized.

As is more clearly depicted on FIG. 10B, the hook end 20 is mounted upona part of a rim “R” of a toilet bowl “WC”. The second part is suspendedby eyelet 44 such that the compressed solid block 50 is positionedadjacent to or upon the inner sidewall “SW” of the toilet bowl WC. Inthis manner, flush water released from the rim downwardly into thetoilet bowl WC contacts the compressed solid block 50 to form atreatment composition which is used to treat the toilet bowl.

While a cooperating hanger peg 40 and eyelet 44 exemplified oneembodiment of a useful fastener means which may be used to assemble acageless lavatory device 10 within the meaning of the invention, it iscontemplated that any other effective means, particularly mechanicalmeans and/or chemical means may be used as well and is considered to bewithin the scope of the invention, although not specifically depicted inthe figures.

FIGS. 11A and 11B depict two views of an embodiment of a two-partcageless lavatory device 10 of the invention configured for use as anITC device.

FIG. 11A depicts a perspective view of a two-part cageless lavatorydevice 10 comprising a first part, a rigid hook end 20 adapted to besuspended upon the rim “R” of a toilet cistern “C”, and a second part, astalk 16 having a sloped, tenon-shaped proximal end 46 inserted in asuitably shaped mortise 19 present in the hook end 20, and at its distalend a plate 30 encased by a compressed solid block 50. The stalk 16 isof sufficient length that between flushes of the toilet to which it isattached, the block 50 is submerged beneath the water line “WL” so thatthe water contacts the block 50 to form a treatment composition withinthe cistern C.

FIG. 11B depicts a top view of the two-part cageless lavatory device 10of FIG. 11A. As is more clearly visible the mortise 19 includes twosloped mortise sidewalls 19′ which abut correspondingly shaped tenonsidewalls 46′ of the proximal end 46 of the stalk 16. Further, as ismore apparent from FIG. 11A the tenon sidewalls 46′ of the proximal end46 of the stalk 16 are seen to taper inwardly toward one another aswell, as well as the two sloped mortise sidewalls 19′ which areconfigured to correspondingly conform.

FIG. 12A and FIG. 12B depict respectively a front sectional view of acompressed solid block 50 encasing/enrobing a plate 30 which dependsfrom a stalk 16, while FIG. 12B depicts the side view of the foregoing.As is depicted on FIG. 12B, there is depicted a compressed solid block50 encasing the plate 30 as well as the stalk 16 extending outwardlyfrom the compressed solid block. The compressed solid block has athickness “TB” as well as a height “HB”. FIG. 12B illustrates apreferred embodiment of the invention, namely wherein the plate 30 ispositioned on the interior of the block 50 and is in a plane parallel tothe mid-plane “MP” which bisects the block 50 and is between themid-plane MP and the front face 53 of the block 50. The front face 53 ofthe block 50 is the face which faces the interior of a sanitaryappliance, here the interior of a toilet bowl WC, while the back face 55is intended to be positioned adjacent to or abutting the interiorsidewall SW of the toilet bowl WC.

Further depicted on FIG. 12B is a sectional line “ZZ” which is intendedto indicate a cross section of the block 50 coincident with a face ofthe plate 30. Returning to FIG. 10A, this sectional view referred to isdepicted. As can be understood with reference to the figure the crosssectional area of the base has dimension 30A, which is less than abouthalf of the surface area AB of the section of the compressed solid block50 which is coincident with the face of the plate 30. More accurately,it should be understood that the calculation of respective ratios of theplate area, 30A to the cross sectional area of the block, AB, is madewith the plate 30 being removed from the compressed solid block so thatthe area AB is unobscured.

FIG. 13 illustrates a sectional view of a cageless lavatory deviceaccording to the invention installed within the interior of a toiletbowl WC. The embodiment illustrated on the following FIGS. 14A, 14B and14C. As is visible from the FIG. 13, the block is positioned adjacent tothe interior sidewall SW of the toilet bowl WC. During the flush cycle,the flow of flush water (indicated by arrows “F”) flows about the block50 wherein the water dissolves at least part of the compressed solidblock 50 composition to form a treatment composition which is used totreat the toilet bowl WC.

FIGS. 14A, 14B and 14C illustrate further views of a cageless lavatorydevice 10 in various views. With reference to FIG. 14A, therein isdepicted a cageless lavatory device 10 which includes a hanger 16,having at its proximal end a hook end 20, and at its distal end adepending plate 30 embedded within a compressed solid block composition50. For the sake of clarity in these figures, the compressed solid blockis illustrated in phantom. With reference now to FIG. 14B therein isillustrated the cageless lavatory device 10 in a rear plan view. As isillustrated in the figure, the respective areas of the plate 30A and thearea AB of the block 50 at the transverse plane coincident with a faceof the plate 30A, further illustrating a preferred ratio of these twosurface areas. FIG. 14C illustrates a side view of the cageless lavatorydevice 10 illustrating the relationship of the placement of the plate 30within the block 50. More specifically the plane of the plate 30 isbetween the mid-plane MP and the front face 53 of the block 50.

FIG. 15 illustrates a hanger 10 comprising a hook end 20 comprising anend member 12 flexibly attached to a top member 14 as well as part ofthe stalk 16. Depending from the end of the stalk 16 distally from thehook end 20 is a plate 30. As can be seen from the perspective viewprovided by FIG. 15, the plate itself is generally planar and oblate inconfiguration, and it is coplanar with the ribbon-type or strip-typeconfiguration and construction of both the stalk 16 and hook end 20. Theplate 30 has a width dimension “W1” as well as a height dimension “H1”and as depicted, desirably the width is greater than the height. As isvisible from the figure, the hanger 10 is generally symmetrical about acenter line “CL” which is drawn with respect to the midline of the stalk16. The center line does not exist as an actual element of the devicebut is illustrated for the sake of convenient reference. As is alsovisible in the figure, a portion of the stalk 16 is configured to extendrearwardly, namely in the direction of the hook end 20 to form astandoff section 80. In the embodiment depicted, the standoff sectioncomprises a first stalk segment 82 which extends rearwardly from thestalk 16 to a peak point 86, and a second stalk segment 84 which extendsrearwardly from the stalk 16 to the same peak point 86. As is visible inthe depicted embodiment of FIG. 15, the stalk 16, first stalk segment82, peak point 86, second stalk segment 84 and the plate 30 are allintegrally formed as parts of the hanger 10. This is not required, butis preferred in certain embodiments as such requires no assemblysubsequent to the initial fabrication of the hanger 10. As is alsovisible, the standoff section 80 is a conveniently formed by the shapeof the hanger 10 to include the first stalk segment 82, second stalksegment 84 and intermediate peak point 86 which is formed by bends orother junctures between the respective segments and between therespective segments and the stalk 16 or plate 30. In the embodimentshown, the length of the first stalk segment 82 and the second stalksegment 84 of the standoff section 80 are of equal lengths. While notillustrated with sufficient particularity in the figure, it is of courseunderstood that the plate, stalk 16 and the hook end 20 all have athickness which may be consistent throughout, or which can vary.

FIG. 16 depicts a side view of a further embodiment of a hanger 10 inparts similar to that depicted on FIG. 15. As is more clearly seen inthis figure, the hook end 20 is formed from first and second elements12, 14 and part of the stalk 16. In the embodiment shown, the length ofthe first stalk segment 82 and the second stalk segment 84 of thestandoff section 80 are of different lengths, specifically the length ofthe first stalk segment 82 is greater than that of the second stalksegment 84. Depending from the stalk 16 is the plate 30. In thisembodiment the plate 30 has a thickness “T1” which is greater than thethickness “T2” of the stalk 16 and the hook end 20. Of course, it willbe understood that each of the hook end, stalk, and plate can havedifferent thicknesses or can all share the same thickness as illustratedin FIG. 1.

FIGS. 17 and 18 depict a further embodiment of a hanger 10 in which thehook end 20 is a flexible element, and a standoff element 80 which isintermediate the hook end and the plate 30 of the hanger. The standoffelement 80 extends rearwardly from a part of the stalk 16 in the samedirection as the hook end 20 extends from the stalk 16. While the hookend is integrally formed with stalk 16 and is proximate to the plate 30,the standoff element 80 may be a discrete element which may be affixedto a part of the hanger 10, advantageously to a part of the stalk 16 byany suitable means. Inter alia, such means may be mechanical means suchas interlocking elements such as cooperating snap-fittings and/orchemical means such as an adhesive or by welding or fusing of theseelements. As can be seen from the figures, the hook end is comprised ofa first hook element 12 flexibly connected to second hook element 13which is in turn connected to a top element 14 which in turn is flexiblyconnected to the stalk 16. At the end of the stalk 16 opposite the hookend, viz, the distal end of the stalk depends the plate 30, here havingan planar, oblate configuration. As is further visible from FIG. 3, theplate 30 is substantially planar in configuration has a width W1 as wellas height H1 and is symmetric around the center line CL of the stalk 16.The plate has a generally linear bottom edge 39 at opposite ends thereofto generally straight end walls 36, 38 which end walls proceed andextend to the stalk 16 via sloping top walls 32, 34.

While not specifically FIGS. 17 and 18 it is to be understood that thehook end 20 of the hanger 10 is depicted in a first, “folded”configuration which permits for the hanger 10 to be compact andconveniently packaged. However, when at least the hook end 20 of thehanger 10 is fabricated of a flexible material, the elements of the hookend 20, especially the a first hook element 12 flexibly connected tosecond hook element 13 may be flexed to form the hook end 20 so that itmay be placed about the rim of a portion of a sanitary device, i.e. atoilet bowl. This action imparts tension to the hook end 20 and alsocauses the hook end to 20 impart a degree of gripping to that portion ofthe rim upon which it is mounted. This is turn helps retain the relativeposition of the hook end, as well as that of the cageless lavatorydevice until repositioned, or removed by a consumer.

FIGS. 19A through 10F depict in various views a preferred embodiment ofa hanger 10 according to the invention, both with and without thecompressed solid block composition 50 affixed to the plate 50. Thepreferred hanger is advantageously used in the process for manufactureof a cageless lavatory device as described herein.

FIG. 19A depicts a one-piece hanger 10 formed of a flexible material,e.g., a thermoplastic polymer. The hanger 10 comprises a hook end 20comprising a first hook element 12, a second hook element 13 and a topmember 14 which in turn is connected to a downwardly extending stalk 16,which terminates in plate 30. Intermediate the hook end 20 and the plate30, a portion of the stalk 16 is configured to extend rearwardly, namelyin the direction of the hook end 20 to form a standoff section 80. Asdepicted, the standoff section comprises a first stalk segment 82 whichextends rearwardly from the stalk 16 to a peak point 86, and a secondstalk segment 84 which extends rearwardly from the stalk 16 to the samepeak point 86. As is visible in the depicted embodiment of FIG. 1. thestalk 16, first stalk segment 82, peak point 86, second stalk segment 84and the plate 30 are all integrally formed as parts of the hanger 10. Inthe embodiment depicted, the length of the first stalk segment 82 andthe second stalk segment 84 are unequal, with the former being greaterthan the latter. The plate 30 is a generally flat planar plate having amaximum width W1 which is at least 1.2 times the dimension of itsmaximum height H1. The plate 30 depends from a part of the stalk 16 andis a symmetrical about the center line “CL” of the stalk 16. The plate30 also has a thickness T1, and as illustrated on the figure, has topedges 31 which are generally straight and are angled downwardly withrespect to the stem 16. The top edges 31 continue to the region of theside vertices 32 of the plate 30 which are rounded. The plate 30 is alsogenerally symmetrical about a line which would extend between the twoside vertices 32 of the plate 30.

While not disclosed in the figure, it is to be understood that the hookend 20 is flexible and in the figures shown are in a foldedconfiguration. However, the elements of the hook end may be readilyunfolded by a consumer so to adapt the hanger 10 to be suspended upon apart of a sanitary appliance.

FIG. 19B depicts a frontal view of the hanger of FIG. 10A. As is visiblein that figure, the plate 30 includes is essentially flat and planar,and excludes any perforations passing therethrough as well as excludingany outwardly extending from either the front face 37 or the rear face37′ of the plate 30.

FIG. 19C depicts a side view of the hanger 10 of prior FIGS. 19A and19B. As is more evident from the figure, the standoff section 80 extendsin the same direction as that of the hook end 20, and particularly atleast the top element 14 which extends rearwardly from the stalk 16. Asmay be also understood from the figure, in preferred embodiments thehook end 20 and the standoff section 80 are preferably coplanar withrespect to one another, while the plate 30 is preferably approximatelyperpendicular to this plane within which the hook end 20 and thestandoff section 80 are coincident. Also more clearly visible is theabsence any outwardly extending from either the front face 37 or therear face 37′ of the plate 30.

FIG. 19D is a further illustration of the hanger 10 of FIG. 19C howeverthe figure further illustrates a compressed solid block 50 encasing thehanger 30 and here, also part of the stalk 16 immediately adjacent tothe plate 30. The said block 50 is depicted in phantom for sake ofconvenient review of the features of the hanger 10. The compressed solidblock 50 has a thickness “TB” as well as a height “HB”. FIG. 10Dillustrates a preferred embodiment of the invention, namely wherein theplate 30 is positioned on the interior of the block 50 and is in a planeparallel to the mid-plane “MP” which bisects the block 50 andparticularly is between the mid-plane MP and the front face 53 of theblock 50. The front face 53 of the block 50 is the face which faces theinterior of a sanitary appliance, here the interior of a toilet bowl WC,while the back face 55 is intended to be positioned adjacent to orabutting the interior sidewall SW of a sanitary appliance, particularlythat of a toilet bowl WC.

FIG. 19E illustrates a frontal view of the embodiment depicted on FIG.19D. For sake of convenience, the plate 30 embedded within the solidcompressed block 50 is depicted in phantom. As is illustrated in thefigure, the respective areas of the plate 30A and the area AB of theblock 50 at the transverse plane coincident with a face of the plate30A, further illustrating a preferred ratio of these two surface areas.

FIG. 19F illustrates a top and side perspective view of the cagelesslavatory device of prior FIGS. 19D and 19E illustrating the relationshipof the placement of the plate 30 within the block 50. More specifically,as is readily visible from the figure, the plane of the plate 30 isbetween the mid-plane MP and the front face 53 of the block 50.

It is to be understood that cageless the lavatory device according tothe invention as well as may be produced by a process according to theinvention may also have a different geometry, configuration or andappearance than the embodiments described in the Figures and still beconsidered to fall within the scope of the invention.

FIG. 20 illustrates a series of process steps which illustrate oneembodiment of the improved process for the manufacture of cagelesslavatory devices disclosed herein.

With reference to FIG. 20, thereon is depicted by virtue of schematicrepresentations a process 100 for the manufacture of cageless lavatorydevices disclosed herein.

In accordance with the process, a premixed block composition oralternately the constituents required to form a block composition isprovided to the inlet hopper 112 of an extruder. The extruder may be asingle screw extruder or a multiple screw extruder. Where plural screwsare present, the screws may be co-rotating or may be counter-rotating.If not previously mixed or blended prior to introduction into theextruder, the block composition is formed into a generally homogeneousmass and exits the extruder via a suitable die 114 which has an orificeprofile of suitable dimensions. Advantageously the die has aconfiguration as generally depicted on FIG. 21. After exiting the die114, measured lengths or measured masses of the extrudate 150 areseparated such as by cutting using a cutting blade or chain cutter 120into preforms of approximately like dimensions and/or mass.

Wherein the die does not shape the extrudate to include a cavity,channel or recess within the extrudate of suitable dimensions to acceptat least the plate of a hanger, an additionally process step may bepracticed although not illustrated in the figure. In a channel-cuttingstep, a channel cutting means such as a saw, or other cutting device isapplied to the extrudate or alternately to the preforms in order tosplit or shape the preform adequately to provide such a suitable sizedchannel or recess. Such a channel or recess advantageously extendslongitudinally through the extrudate and/or the block which facilitatesconvenient positioning of the plate of the hanger in the next processstep. Alternately, subsequent to extrusion the preforms may be partiallysplit using an suitable tool means, such as a plunging blade which maybe used to partially split a portion of a preform in order to provide acavity or slot which is of sufficient width and depth to accommodate atleast the plate of the hanger. Such a cavity formed by such bladetypically does not extend across the length of the preform nor throughthe ends thereof.

Conveniently however, as the extrudate exits the die a channel isprovided by extruding through a die which includes a blade or othercutter means which extends into the open cross-section of the die suchthat as the extrudate exits the die, it is provided with such a channelwhich partially splits the extrudate into the legs of a “V”, whichremain attached however at the base of each leg. Such a channel mayextend across the length of the preform and through the ends thereof.Alternately, subsequent to extrusion a tool. An exemplary die comprisingsuch a blade is depicted on FIG. 21. Therein is depicted a plan view ofa flat die having a die body 182 and a shaped orifice 184 passingtherethrough. Extending from one side 186 of the orifice 184 is acutting member 188, here in the shape of a plough which extends into theinterior of the orifice. Advantageously the cutting member 188 ploughsthrough the extrudate passing through the die orifice 184 to form anextrudate which is partially split into the legs of a “V” such as isillustrated on FIG. 22. As is seen from FIG. 22, the hot extrudate tendsto deform slightly and open up the distance between the two legs 190,192 of the “V” which is advantageous in that it often facilitates thelater insertion of the plate prior to the die compression step of theprocess. As is also seen from FIG. 22, according to preferredembodiments, when the extrudate 150 of alternately a preform is split orotherwise shaped to provide a channel, cavity or slot, the thickness ofthe block within the two legs 190, 192 is unequal, as depicted on bothFIGS. 22 and 23. As is visible, the thickness of one part of the blockat one side of the channel 170, i.e., thickness 190T of block part 190has a lesser thickness dimension than the thickness of the block at theopposite side of the channel, viz., thickness 192T of block part 190.Preferably the channel 170 is then formed to be at one side but notcoincident with midplane MP, as discussed previously. Further, mostpreferably the channel height “CH” is at least one-half, preferably atleast 60%, more preferably at least 70% of the height “H1” of thecompressed block 50 at the end of the process.

In a next process step, the plate 30 of a hanger is inserted within theinterior of the channel 170 or cavity such that the plate is preferablywholly encased within the interior of the preform. Preferably also thehanger extends outwardly from the preform at an angle which isapproximately perpendicular to, more specifically 90°+/−10°, preferably90°+/−5° with respect to tangent of the surface from which point thehanger extends outwardly therefrom. This angle is indicated in FIG. 20as “x” for sake of convenient reference. Such ensures that consistentloading and proper weight distribution of the hook, and proper placementof the cageless device in the sanitary appliance, especially a toilet ismaintained.

Optionally prior to introduction of the preform and hanger into a die inthe next process step, the die compression step, one or more of theinterior surfaces of the die 130 may be sprayed with a mold releasematerial or other lubricant such as mineral oil or a paraffin oil. Thedie 130 is preferably a pair of opposing dies 130 which when compressedby a suitable compression means, such as a ram 132 and anvil 134 formsan intermediate die cavity of a suitable dimension within which thepreform 152 may be placed. Thus, in the die compression step a preform152 having an inserted hanger is introduced between the opposing dies130 and the opposing dies 130 are brought together to both form thecompressed solid block composition and adhere it to the plate 30, aswell as to densify the composition of the compressed solid block by atleast 1.5%, preferably at least 2% more than the density of theextrudate from which the compressed solid block 50 is formed.Advantageously the pressure of the die is at least 500-1500 psi.

The formed cageless lavatory device 10 is removed from the die and isready for use, or alternately may be packaged in a suitable package inorder to form a vendible article.

FIGS. 24A and 24B illustrate a further embodiment of a hanger which maybe used in conjunction with the present invention.

FIGS. 24C and 24D depict a still further embodiment of a cagelesslavatory dispensing device 10 which utilizes the hanger depicted onprior FIGS. 24A and 24B.

In order to further illustrate the present invention, various examplesof preferred embodiments of the invention are described, following. Inthese examples, as well as throughout the balance of this specificationand claims, all parts and percentages are by weight unless otherwiseindicated.

EXAMPLES

Compressed solid blocks according to the invention were produced fromthe described on the following tables; examples according to theinvention are indicated by a letter “E” preceding one or more digits.The compositions recited on Table 1 illustrated non-bleach containingcompositions according to the invention. TABLE 1 E1 E2 E3 E4 E5 E6 E7 E8sodium dodecyl benzene sulfonate (85%) 35 35 35 35 23 23 27 29.2 C₁₄/C₁₆olefin sulfonate, sodium salt (80%) 22 22 22 32 26.4 26.4 25 25.6 sodiumlauryl ether sulfate (80%) — — — 5 — — — — anhydrous sodium sulfate 19.920.9 22.91 21 41.9 42.02 39.92 37.7 lauryl monoenthanolamide 15 15 15 5— — — — anhydrous silica 2 2 2 2 2 2 2 — fragrance 3 3 — — 4 4 4 6.298colorant 0.1 0.1 — — 0.20 0.08 0.08 0.002 mineral oil 3 2 3.09 — 2.5 2.52 1.2 E9 E10 E11 E12 E13 E14 E15 E16 sodium dodecyl benzene sulfonate(85%) 27 23 23 23.5 23 29 23 23 C₁₄/C₁₆ olefin sulfonate, sodium salt(80%) 25 26.42 26.42 26.42 26.4 27 26.4 26.4 sodium lauryl ether sulfate(80%) — — — — — — — — anhydrous sodium sulfate 39.92 42.5 42 41 42 35.9341.9 42.1 lauryl monoenthanolamide — — — — — — — — anhydrous silica 2 22 2 1.5 2 2 2 fragrance 4 4 4 4 4 4 4 4 colorant 0.08 0.08 0.08 0.08 0.10.066 0.2 0.001 mineral oil 2 2 2.5 3 2.5 2.5 2.5 2.5 E17 E18 E19 E20E21 E22 E23 sodium dodecyl benzene sulfonate (85%) 23 23 23 23 23 23 23C₁₄/C₁₆ olefin sulfonate, sodium salt (80%) 26.4 26.4 26.4 26.4 26.426.4 26.4 sodium lauryl ether sulfate (80%) — — — — — — — anhydroussodium sulfate 42.1 42.1 42.1 41.96 42.03 41.47 41.98 laurylmonoenthanolamide — — — — — — — anhydrous silica 2 2 2 2 2 2 2 fragrance4 4 4 4 4 4 4 colorant 0.0022 0.0019 0.084 0.136 0.065 0.126 0.1155mineral oil 2.5 2.5 2.5 2.5 2.5 3 2.5

The identity of the constituents used to form the forgoing compressedsolid blocks are identified more specifically on the following Table 2.The individual constituents were used “as supplied” from theirrespective suppliers and may constitute less than 100% wt, or 100% wt.of the named compound, as indicated on Table 1. If less than 100%, theamount of actives present in the “as supplied” material are indicated inTable 1 and 2. TABLE 2 sodium dodecyl benzene sodium dodecyl benzenesulfonate sulfonate (85%) (85% wt. actives), supplied as UFARYL DL85C₁₄/C₁₆ olefin sulfonate, C₁₄/C₁₆ olefin sulfonate, sodium salt sodiumsalt (80%) (80% wt. actives), supplied as LSS 480/H, or other sourcesodium lauryl ether sulfate sodium lauryl ether sulfate (80% wt. (80%)actives), supplied as EMPICOL ESB 70 anhydrous sodium sulfate anhydroussodium sulfate lauryl monoethanolamide lauryl monoethanolamide, suppliedas COMPERLAN WB, or other source anhydrous silica supplied as MICROSILED, or other source fragrance proprietary composition of its respectivesupplier colorant proprietary composition of its respective suppliermineral oil technical grade mineral oil; technical grade paraffin oilCertain of the foregoing example compositions were subjected to servicelife testing to evaluate compressed solid block compositions used as ITBcageless lavatory devices. In accordance with the tests, ITB cagelesslavatory device were produced in accordance with the foregoingdiscussion in the specification wherein a mass of the compressed solidblock compositions were extruded into a preform, a slot was provided inthe preform, and a hanger generally in accordance with that illustratedin FIG. 3 was provided such that the plate of the hanger was fullyinserted into the slot of the preform. The preform was then subjected toa single compression operation in a suitable die to compress and formthe compressed solid block composition into a block having aconfiguration also generally as depicted on FIG. 14A. The initial massof the compressed solid block composition varied slightly from sample tosample, but initial mass is indicated on the following table.

In accordance with the test samples ITB cageless lavatory devices weresupplied to a toilet, either to a “Remo” model toilet bowl, (ex. ShiresCo., Ireland), or an “Alto” model toilet bowl (ex. Ideal Standard Co,UK). The placement of the ITB device varied but once positioned prior tothe test was not moved until the test was concluded. The test wasperformed over a number of successive days, and all testing wasperformed at approximately room temperature (19-22° C.). Each of thetoilets were periodically and automatically flushed by amachine-controlled device which operated the toilets to flush 12 timesdaily at intervals of 60 minutes between flushes. The appearance of thecompressed solid blocks during the duration of the test were observed,and prior to each new day's testing and the initial flush of the day'stests each of the ITB cageless lavatory devices were removed, weighed,and then replaced in their prior position suspended from the rim of atoilet bowl. In this manner, the loss of the mass of essentially drycompressed solid blocks were evaluated at regular intervals. In thefollowing test, four sample devices including a compressed solid blockcomposition according to E3, as well as four sample devices including acompressed solid block composition according to E4 were tested. Theresults of the test are indicated on the following Table 3. TABLE 3 %mass % mass % mass loss of loss of loss of Initial mass of compressedcompressed compressed compressed solid block solid block solid blockSample #/ solid block following following following composition (grams)159 flushes 205 flushes 253 flushes 1/E4 112.3 26.19 36.82 82.14 2/E4104.9 4.69 7.05 47.49 3/E4 106.2 28.96 38.11 85.95 4/E4 110 4.44 6.5044.45 5/E3 98.9 1.62 4.16 49.73 6/E3 109.5 10.90 18.53 60.76 7/E3 107.23.97 9.29 55.80 8/E3 100.8 13.98 20.25 65.80During the test and following the conclusion of the test, no breakingoff of the compressed solid block compositions were observed,demonstrating surprisingly effective adhesion of the compositions to theplate notwithstanding multiple flush cycles wherein flowing waterdelivered from the rim of the toilet impinging directly on the plate andthe respective compositions. The compositions also delivered aneffective amount of the surfactants present in the blocks as evidencedby the formation of bubbles or foam at the waterline of the toilet bowlfollowing a flush cycle.

The disparities in the rate of dissolution of the tested sample devicesat like numbers of flushes may often attributed to the placement of thesample with respect to specific positions on the rim of the toilet bowl,as in some positions greater volumes of water were released with eachflush and tended to erode or dissolve the compressed block compositionmore quickly than at other positions. Such is not considered to be adetriment, but rather permits the consumer to selectively place the ITBcageless lavatory devices to provide a degree of control over the usefullife of the block, and upon the degree of foaming which is desiredfollowing individual flushes of the toilet bowl.

Additional sample ITB cageless lavatory devices based on compressedblock compositions according to further examples described on Table 1were also subjected to testing generally according to the procedureoutlined above. In accordance with the test, samples were supplied to an“Alto” model toilet bowl (ex. Ideal Standard Co, UK). The placement ofthe ITB device varied but once positioned prior to the test was notmoved until the test was concluded. The test was performed over a numberof successive days, and all testing was performed at approximately roomtemperature (19-22° C.). Each of the toilets were periodically andautomatically flushed by a machine-controlled device which operated thetoilets to flush 16 times during each day of testing at intervals ofapproximately 60 minutes between flushes. The appearance of thecompressed solid blocks during the duration of the test were observed,and prior to each new day's testing and the initial flush of the day'stests each of the ITB cageless lavatory devices were removed, weighed,and then replaced in their prior position suspended from the rim of atoilet bowl. In this manner, the loss of the mass of generally drycompressed solid blocks were evaluated at regular intervals. The resultsof the test are outlined on the following Table 4. Multiple replicatesamples of each cageless lavatory device of respective compressedlavatory block compositions were produced and individually tested. TABLE4 % mass % mass % mass loss of loss of loss of Initial mass ofcompressed compressed compressed compressed solid block solid blocksolid block Sample #/ solid block following following followingcomposition (grams) 195 flushes 338 flushes 354 flushes 1/E9 34.87 —48.9  — 2/E9 38.62 — 46.22 — 3/E9 40.83 — 70.78 — 4/E9 39.11 — 65.53 —5/E9 40.81 — 69.35 — 6/E9 40.29 — 43.93 — 7/E9 39.47 — 31.67 — 8/E938.82 39.09 — — 9/E9 39.68 35.91 — — 10/E9  35.55 63.28 — — % mass %mass loss of loss of compressed compressed Initial mass of solid blocksolid block Sample #/ compressed solid following following compositionblock (grams) 150 flushes 165 flushes 1/E13 65.10 25.94 — 2/E13 75.5844.92 — 3/E13 68.90 41.34 — 4/E13 64.53 — 27.45 5/E13 64.18 — 21.146/E13 66.58 — 29.68 7/E13 66.38 — 31.89 % mass loss of compressedInitial mass of solid block Sample #/ compressed solid followingcomposition block (grams) 172 flushes 1/E14 64.09 21.86 2/E14 66.69 5.453/E14 62.73 21.44 4/E14 68.86 14.91 5/E14 63.51 10.94

Again, perceived disparities in the rate of dissolution of the testedsample devices at like numbers of flushes may often attributed to theplacement of the sample with respect to specific positions on the rim ofthe toilet bowl. Such is not considered to be a detriment, but ratherpermits the consumer to selectively place the ITB cageless lavatorydevices to provide a degree of control over the useful life of theblock, and upon the degree of foaming which is desired followingindividual flushes of the toilet bowl.

Still further sample ITB cageless lavatory devices based on compressedblock compositions according to further examples described on Table 1were also subjected to an “accelerated” testing protocol generallyaccording to the procedure outlined above except that the toilets wereflushed 40 times per each day of the test. In accordance with the test,samples were supplied to a Brazilian toilet bowl. The test was performedover a number of successive days, and all testing was performed atapproximately room temperature (19-22° C.). The placement of the ITBdevice varied but once positioned prior to the test was not moved untilthe test was concluded. Each of the toilets were periodically andautomatically flushed by a machine-controlled device which operated thetoilets to flush 40 times during each day of the test at intervals of 30minutes between flushes. The appearance of the compressed solid blocksduring the duration of the test were observed, and prior to each newday's of testing and the initial flush of the day's tests each of theITB cageless lavatory devices were removed, weighed, and then replacedin their prior position suspended from the rim of a toilet bowl. In thismanner, the loss of the mass of essentially dry compressed solid blockswere evaluated at regular intervals. The results of the test ouroutlined on the following Table 5. TABLE 5 % mass loss of compressedInitial mass of solid block Sample #/ compressed solid followingcomposition block (grams) 165 flushes 1/E20 37.89 54.84 2/E20 37.07 20.93/E20 37.53 72.92 4/E20 39.88 36.83 5/E20 37.84 19.47 6/E21 38.07 25.487/E21 39.39 39.42 8/E21 34.47 40 9/E21 38.37 26.55 10/E21  38.06 23.1411/E21  37.69 28.04

Yet again, perceived disparities in the rate of dissolution of thetested sample devices at like numbers of flushes may often attributed tothe placement of the sample with respect to specific positions on therim of the toilet bowl, as in some positions greater volumes of waterwere released with each flush and tended to erode or dissolve thecompressed block composition more quickly than at other positions. Suchis not considered to be a detriment, but rather permits the consumer toselectively place the ITB cageless lavatory devices to provide a degreeof control over the useful life of the block, and upon the degree offoaming which is desired following individual flushes of the toiletbowl.

Yet further sample ITB cageless lavatory devices based on compressedblock compositions according to further examples described on Table 1were also subjected to an “accelerated” testing protocol generallyaccording to the procedure outlined above except that the toilets wereflushed 40 times per each day of the test. In accordance with the test,samples were supplied to a model “Alto” toilet bowl as described above.The test was performed over a number of successive days, and all testingwas performed at approximately room temperature (19-22° C.). Each of thetoilets were periodically and automatically flushed by amachine-controlled device which operated the toilets to flush 40 timesduring each day of the test at intervals of 30 minutes between flushes.The placement of the ITB device varied but once positioned prior to thetest was not moved until the test was concluded. The appearance of thecompressed solid blocks during the duration of the test were observed,and prior to each new day's of testing and the initial flush of theday's tests each of the ITB cageless lavatory devices were removed,weighed, and then replaced in their prior position suspended from therim of a toilet bowl. In this manner, the loss of the mass ofessentially dry compressed solid blocks were evaluated at regularintervals. The results of the test our outlined on the following Table6. TABLE 6 % mass loss of compressed Initial mass of solid block Sample#/ compressed solid following composition block (grams) 172 flushes1/E22 39.54 54.29 2/E22 37.79 44.40 3/E22 37 13.62 4/E22 38.69 37.965/E22 38.6 54.55 6/E22 38.41 48.89 7/E22 37.63 10.37 8/E23 36.88 48.699/E23 36.63 37.45 10/E23  36.42 20.86 11/E23  38.48 39.83 12/E23  35.8536.93 13/E23  38.53 57.69 14/E23  37.88 36.35

Yet again, perceived disparities in the rate of dissolution of thetested sample devices at like numbers of flushes may often attributed tothe placement of the sample with respect to specific positions on therim of the toilet bowl, as in some positions greater volumes of waterwere released with each flush and tended to erode or dissolve thecompressed block composition more quickly than at other positions. Suchis not considered to be a detriment but rather permits the consumer toselectively place the ITB cageless lavatory devices to provide a degreeof control over the useful life of the block, and upon the degree offoaming which is desired following individual flushes of the toiletbowl.

It is to be specifically noted that each of the foregoing tested sampleITB cageless lavatory devices exhibited a satisfactory service life andnone of the tested samples exhibited breakage or delamination of thecompressed solid block composition from the plate of the hanger.

While the invention is susceptible of various modifications andalternative forms, it is to be understood that specific embodimentsthereof have been shown by way of example in the drawings which are notintended to limit the invention to the particular forms disclosed; onthe contrary the intention is to cover all modifications, equivalentsand alternatives falling within the scope and spirit of the invention asexpressed in the appended claims.

1. A process for the manufacture of a lavatory dispensing device whichprovides at least one treatment composition to a sanitary appliancewhich method comprises the steps of: providing a composition to anextruder; forming an extrudate from said composition; inserting part ofa hanger into said extrudate; compressing the extrudate to encase orenrobe said part of a hanger thereby forming said lavatory dispensingdevice.
 2. A process according to claim 2 wherein: subsequent toextrusion and prior to insertion of the hanger, the extrudate is cutinto preforms.
 3. A process according to claim 1 wherein: during theextrusion of the extrudate a channel is formed in the extrudate.
 4. Aprocess according to claim 2, wherein: a channel or cavity is formed inthe preforms.
 5. A process according to claim 1, wherein: the extrudateis compressed to form a compressed solid block such that density of thecompressed solid block as at least 1% greater than the density of thedensity of the extrudate.
 13. A process according to claim 1 wherein theat least one treatment composition is a sanitizing composition.
 14. Aprocess for the manufacture of a cageless lavatory dispensing devicewhich provides at least one treatment composition to a toilet bowl whichmethod comprises the steps of: providing a composition to an extruder;forming an extrudate from said composition; inserting part of a hangerinto said extrudate; compressing the extrudate so to densify thecomposition by at least 1.5% and to at least partially encase or enrobesaid part of a hanger thereby forming said lavatory dispensing device.15. A process according to claim 14 wherein the composition is densifiedby at least 2%.
 16. A process according to claim 14 wherein theextrudate is compressed in a die at a die pressure of at least 500 psi.